Page 2 - SAFETY; WITH, COULD RESULT IN PERSONAL INJURY OR DEATH.; NOTICE TO USERS OF THIS MANUAL
SAFETY Throughout this publication, “DANGER!” and “CAUTION!” blocks are used to alert the mechanic to special instructions concerning a particular service or operation that might be hazardous if performed incorrectly or carelessly. PAY CLOSE ATTENTION TO THEM. * DANGER! UNDER THIS HEADING WILL BE FO...
Page 3 - Table of Contents
Table of Contents Page 1 SAFETY ........................... INSIDE FRONT COvER SECTION 1: GENERATOR FUNDAMENTALS ....................... 3-7 MAGNETISM ................................................................ 3ELECTROMAGNETIC FIELDS .................................... 3ELECTROMAGNETIC INDUCT...
Page 5 - MAgNETISM; • The increase in the number of lines of force is; ELECTROMAgNETIC INdUCTION; Figure 1-3. – A Simple Revolving Field Generator
Section 1 GENERATOR FUNDAMENTALS MAgNETISM 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. However, there are certain pat- terns of behavior that are known. Application of these behavior ...
Page 6 - A SIMPLE AC gENERATOR; Figure 1-5. – Alternating Current Sine Wave; A MORE SOPHISTICATEd AC gENERATOR; Figure 1-6. – A More Sophisticated Generator
Section 1GENERATOR FUNDAMENTALS A SIMPLE AC gENERATOR Figure 1-4 shows a very simple AC Generator. The generator consists of a rotating magnetic field called a ROTOR and a stationary coil of wire called a STATOR. The ROTOR is a permanent magnet which consists of a SOUTH magnetic pole and a NORTH mag...
Page 7 - Figure 1-7. – Generator Operating Diagram
Section 1 GENERATOR FUNDAMENTALS NOTE: AC output frequency at 3720 rpm will be about 60 Hertz. The “No-Load” is set slightly high to prevent excessive rpm, frequency and voltage droop under heavy electrical loading. Generator operation may be described briefly as fol- lows:1. Some “residual” magneti...
Page 8 - Caution! Do not overload the generator. Some; Model
Section 1GENERATOR FUNDAMENTALS FIELd BOOST When the engine is cranked during startup, the starter contactor is energized closed. Battery voltage is then delivered to the starter motor and the engine cranks.During cranking, battery voltage flows through a resis- tor and a field boost diode in the Pr...
Page 9 - Figure 1-8. – Connection for 120 Volts Only
Section 1 GENERATOR FUNDAMENTALS Figure 1-8. – Connection for 120 Volts Only RECONNECTION FOR DUAL VOLTAGE OUTPUT:When connected for 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...
Page 11 - Stator; BRUSH HOLdER; • Two (2) SENSING leads deliver ACTUAL AC output; VOLTAGE
Section 2 MAJOR GENERATOR COMPONENTS Leads 2 & 6 = Stator Excitation WindingLeads 11S & 22S = Voltage Sensing LeadsLeads 11 & 22, 33 & 44 = AC Power Windings Stator 2 6 11 22 33 44 11S 22S Figure 2-2. – Stator Output Leads BRUSH HOLdER The brush holder is retained in the rear bearing...
Page 12 - CRANkCASE BREATHER; GASKET
Section 2MAJOR GENERATOR COMPONENTS NOTE: If, for any reason, sensing voltage to the regulator is lost, the regulator will shut down and excitation output to the Rotor will be lost. The AC output voltage will then drop to a value that is commensurate with Rotor residual magnetism (about 7-12 VAC). W...
Page 13 - CONTROL PANEL COMPONENT IdENTIFICATION
Section 2 MAJOR GENERATOR COMPONENTS Page 11 REAR VIEW CONTROL BOARD (PCB) WITH J1 CONNECTOR GOVERNOR ACTUATOR J2 CONNECTOR STARTER CONTACTOR RELAY (SCR) TERMINAL BLOCK (TB) “4-TAB CONNECTOR” VOLTAGE REGULATOR (VR) WITH RED LED START/STOP SWITCH (SW1) WITH RED LED 7.5 AMP DC FUSE (F1) CIRCUIT BREAKE...
Page 14 - DANGER! INSULATION RESISTANCE; dRYINg THE gENERATOR; NOTE: A shop that repairs electric motors may; CAUTION!: Some generators may use epoxy
Section 3INSULATION RESISTANCE TESTS EFFECTS OF dIRT ANd MOISTURE Moisture and dir t are detrimental to the continued good operation of any 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 w...
Page 15 - vents that will not attack such materials.; STATOR INSULATION RESISTANCE
Section 3 INSULATION RESISTANCE TESTS vents that will not attack such materials. Use a soft brush or cloth to apply the solvent. Be careful to avoid damage to wire or winding insulation. After cleaning, dry all components thoroughly using moisture-free, low-pressure compressed air. * DANGER!: DO NOT...
Page 16 - TESTINg ROTOR INSULATION; ExAMPLE: generator is rated at 120 volts AC.; ROTOR MINIMUM INSULATION RESISTANCE:
Section 3INSULATION RESISTANCE TESTS Leads 2 & 6 = Stator Excitation WindingLeads 11S & 22S = Voltage Sensing LeadsLeads 11 & 22, 33 & 44 = AC Power Windings Stator 2 6 11 22 33 44 11S 22S Figure 3-2. – Stator Leads TESTINg ROTOR INSULATION To test the Rotor for insulation breakdown,...
Page 17 - METERS
Section 4 MEASURING ELECTRICITY METERS Devices used to measure electrical proper ties are called meters. Meters are available that allow one to measure (a) AC voltage, (b) DC voltage, (c) AC frequency, and (d) resistance in ohms. The following apply: ❏ To measure AC voltage, use an AC voltmeter. ❏ T...
Page 18 - MEASURINg CURRENT; NOTE: If the physical size of the conductor or; MEASURINg RESISTANCE
Section 4MEASURING ELECTRICITY Correct engine and Rotor speed is maintained by a stepper motor governor. For models rated 60 Hertz, the governor is generally set to maintain a no-load fre- quency of about 60 Hertz with a corresponding output voltage of about 124 volts AC line-to-neutral. MEASURINg C...
Page 19 - ELECTRICAL UNITS; OHM’S LAW; OHMS
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...
Page 20 - INTROdUCTION; The engine DC control system includes all com-; OPERATIONAL ANALYSIS
SC - STARTER CONTACTOR TB - TERMINAL BLOCK, 4 TAB SP2 - SPARK PLUG, CYL. 2 SP1 - SPARK PLUG, CYL. 1 LED - ALARM INDICATORLOP - LOW OIL PRESSURE SWITCH SCR - STARTER CONTACTOR RELAYSM - STARTER MOTOR SW1 - PRIME/START-RUN-OFF SWITCH FS - FUEL SOLENOID FP - FUEL PUMP F1 - FUSE, 7.5A CH - CHOKE HEATERC...
Page 24 - PRINTEd CIRCUIT BOARd; PIN; J1 CONNECTOR; BATTERY
Section 5ENGINE DC CONTROL SYSTEM PRINTEd CIRCUIT BOARd GENERAL:The Printed Circuit Board (PCB) mounted inside the generator control panel is responsible for crank- ing, startup, running and shutdown operations. The board interconnects with other components of the DC control system to turn them on a...
Page 25 - NOTE: Water cannot be added to some “mainte-
Section 5 ENGINE DC CONTROL SYSTEM cold weather starting, voltage drop between the bat- tery and starter should not exceed 0.12 volt per 100 amperes of cranking current.Select the battery cables based on total cable length and prevailing ambient temperature. Generally, the longer the cable and the c...
Page 26 - JUMPER WIRE; STARTER CONTACTOR RELAY
Section 5ENGINE DC CONTROL SYSTEM a. With Wire 17 grounded, a Crank Relay on the circuit board energizes and battery voltage is delivered to the Star ter Contactor Relay via Wire 56. The Star ter Contactor Relay energizes, its contacts close and the Starter Contactor is energized via wire 16. Its co...
Page 27 - The “Flow Char ts” in this section may be used in; If Problem Involves AC Output; Problem 1 – Voltage & Frequency Are Both High or Low
Section 6 TROUBLESHOOTING FLOWCHARTS The “Flow Char ts” in this section may be used in conjunction with the “Diagnostic Tests” 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 AC generator only.Beginning with Pr...
Page 28 - Problem 2 –; Generator Produces Zero Voltage or Residual Voltage (5-12VAC)
Section 6TROUBLESHOOTING FLOWCHARTS Page 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 T...
Page 30 - Proble 5 – Priming Function Does Not Work (Gasoline Models)
Section 6TROUBLESHOOTING FLOWCHARTS Page 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...
Page 31 - Problem 6 - Engine Will Not Crank
Section 6 TROUBLESHOOTING FLOWCHARTS Page 29 REPLACE DEFECTIVE SWITCH REPLACE BAD STARTER CONTACTOR RELAY REPLACE STARTER MOTOR IF DEFECTIVE REPLACE STARTER CONTACTOR GO TO PROBLEM 10 RECHARGE OR REPLACE BATTERY – CLEAN, REPAIR OR REPLACE BAD CABLE(S) CHECk WIRING AND WIRE CONNECTIONS. REPAIR, RECON...
Page 32 - Problem 7 – Engine Cranks But Will Not Start (Gasoline Units)
Section 6TROUBLESHOOTING FLOWCHARTS Page 30 CLEAN AND REGAP OR REPLACE SPARK PLUG REPLACE BAD SWITCH REPLACE FUEL PUMP REPLACE SOLENOID REPLACE MAGNETOS ADJUST OR REPAIR ADJUST OR REPAIR ADJUST VALVES REPLENISH FUEL SUPPLY O.K. BAD Problem 7 – Engine Cranks But Will Not Start (Gasoline Units) (Overc...
Page 34 - Problem 8 – Engine Starts Hard and Runs Rough (Gasoline Units)
Section 6TROUBLESHOOTING FLOWCHARTS Page 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 SUPPLY LOW FUEL ENGINE MISS IS APPARENT TEST 29 – CH...
Page 35 - Problem 8 – Engine Starts Hard and Runs Rough (LP Units)
Section 6 TROUBLESHOOTING FLOWCHARTS Page 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 SUPPLY LOW FUEL ENGINE MISS IS APPARENT TEST 29 – CHECK IGNITION SPARK TEST 30 – CHECK SPARK PLUGS CLEAN AND REGAP...
Page 36 - Problem 9 – High Oil Temperature Fault (6 Flashes)
Section 6TROUBLESHOOTING FLOWCHARTS Page 34 Problem 9 – High Oil Temperature Fault (6 Flashes) or Low Oil Pressure Fault (5 Flashes) REPAIR OR REPLACE REPLACE SWITCH HIGH OIL TEMPERATURE – 6 FLASHES ON SW1 LED TEST 38 – CHECK OIL TEMPERATURE SWITCH CHECK ENGINE OIL LEVEL TEST 39 – CHECK WIRE 85 FOR ...
Page 38 - Caution! Do not stand in front of carburetor
Section 7DIAGNOSTIC TESTS INTROdUCTION The “Diagnostic Tests” in this chapter may be per- for med in conjunction with the “Flow Char ts” of Section 6. Test numbers in this chapter correspond to the numbered tests in the “Flow Charts”.Tests 1 through 13 are procedures involving problems with the gene...
Page 39 - NOTE: The dip switches on the Printed Circuit; TEST 4 – FIxEd ExCITATION TEST/ROTOR
Section 7 DIAGNOSTIC TESTS 4. If no movement is seen in Step 3 remove the con- trol panel cover. Verify the six pin connector (j2) on the Printed Circuit Board is seated properly, remove the connector and then replace it and test again. Verify the dip switches are correctly set. NOTE: The dip switch...
Page 40 - TEST 4 RESULTS
Section 7DIAGNOSTIC TESTS 6 0 4 13 13 2 4 22S 11S 15 105 VAC JUMPER WIRE WIRES 4 REMOVED FROMVOLTAGE REGULATOR VOLTAGE REGULATOR FUSE HOLDER (F1) RED TEST LEAD BLACK TEST LEAD Figure 7-4. – Fixed Excitation Test, Step B 4. Disconnect Wire 2 from the Voltage Regulator (VR) and connect one meter test ...
Page 41 - TEST 5 – CHECk FIELd BOOST; TEST 6 – TEST STATOR dPE WINdINg
Section 7 DIAGNOSTIC TESTS 6 0 4 13 13 2 4 22S 11S 15 WIRES 4 REMOVED FROMVOLTAGE REGULATOR VOLTAGEREGULATOR FUSE HOLDER (F1) RED TEST LEAD BLACK TEST LEAD 1.11 Amp Figure 7-6. – Fixed Excitation Test, Step D 7. Re-connect Wire 11S and Wire 22S to the Voltage Regulator. 8. Remove the jumper wire bet...
Page 42 - TEST 7 – CHECk SENSINg LEAdS / POWER
Section 7DIAGNOSTIC TESTS A. Schematic B. Pictorial 2 2 6 6 Figure 7-8. – Stator Excitation Winding PROCEDURE:1. Disconnect Wire 2 from the Voltage Regulator.2. Disconnect Wire 6 from the Voltage Regulator.3. Set a VOM to its “Rx1” scale and zero the meter.4. Connect the VOM test leads across the te...
Page 43 - AC POWER WINDING RESISTANCE; TEST 8 – CHECk BRUSH LEAdS
Section 7 DIAGNOSTIC TESTS AC POWER WINDING RESISTANCE * RV45 (Model 5410/5411) ACROSS WIRES: OHMS 11 & 22 0.396 Ω 11S & 22S 0.396 Ω 33 & 44 0.396 Ω AC POWER WINDING RESISTANCE * RV55 (Model 5412/5413) ACROSS WIRES: OHMS 11 & 22 0.28 Ω − 0.32Ω 11S & 22S 0.28 Ω − 0.32Ω 33 & 44...
Page 44 - ROTOR RESISTANCE
Section 7DIAGNOSTIC 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. However, when the generator has been idle for some time, an oxide film can...
Page 45 - TEST 11 – CHECk MAIN CIRCUIT BREAkER; SCHEMATIC; TEST 12 – CHECk LOAd VOLTAgE &
Section 7 DIAGNOSTIC 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 available. A defective breaker may not be able to pass current even though it...
Page 46 - Note: If desired, a pressure gauge can be attached
Section 7DIAGNOSTIC TESTS TEST 14 – TRY CRANkINg THE ENgINE DISCUSSION:If the Star t-Stop Switch on the generator panel is actuated, but the Fuel Pump does not run (priming function doesn’t work), perhaps battery voltage is not available. PROCEDURE:Hold the Start-Stop Switch at “START”. The engine s...
Page 47 - TEST 16 – CHECk 7.5 AMP FUSE
Page 45 Section 7 DIAGNOSTIC TESTS TEST 16 – CHECk 7.5 AMP FUSE DISCUSSION:If the panel-mounted 7.5 amp fuse (F1) has blown, engine cranking will not be possible. Figure 7-15. – 7.5 Amp Fuse PROCEDURE:Push In on fuse holder cap and turn counterclockwise. Then, remove the cap with fuse. Inspect the F...
Page 48 - TEST 19 – CHECk CONTINUITY OF WIRE 17; “Start”; TEST 20 – CHECk START-STOP SWITCH
TEST 19 – CHECk CONTINUITY OF WIRE 17 DISCUSSION:A faulty condition in Wire 17 could prevent the unit from cranking when the Start-Stop switch is held in the “Start” position. PROCEDURE:1. Disconnect Wire 17 from its Switch terminal and connect it to frame ground. The engine should crank. If unit cr...
Page 49 - TEST 21 – CHECk POWER SUPPLY TO
Section 7 DIAGNOSTIC TESTS CONTINUITY DEPRESSEDAWAY FROMTERMINAL BEINGTESTED 8 12 3 7 45 6 0000 Figure 7-18. – Test 20, Step 6 RESULTS:1. If “Continuity” is not measured in Step 3, repair, reconnect or replace Wire 0 (between Start-Stop Switch and ground terminal) as necessary. 2. If the Start-Stop ...
Page 50 - TEST 23 – CHECk STARTER CONTACTOR; STEP 1 TEST POINT; TEST 24 – CHECk STARTER MOTOR
“Infinity” should be measured. Set the Start-Stop Switch to “START”. The meter should now read “Continuity”. Short to Ground:3. Set the VOM 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 terminal from which Wi...
Page 51 - WARNING! DO NOT ROTATE ENGINE WITH; Figure 7-22. – Check Pinion Gear Operation
Section 7 DIAGNOSTIC TESTS be indicated by excessive current draw or no RPM. 3. A defective Starter Motor switch.4. Broken, damaged or weak magnets.5. Starter drive dirty or binding. DISCUSSION:Test 21 verified that Printed Circuit Board action is delivering DC voltage to the Starter Contactor Relay...
Page 52 - Minimum rpm; Note: Nominal amp draw of starter in generator is
Figure 7-23. – Clamp-On Ammeter TACHOMETER:A tachometer is available from your Generac Power 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. – Tachometer TEST BRACkET:A starter motor test bracket may be made as shown in Fi...
Page 53 - TEST 25 – CHECk FUEL SUPPLY; Figure 7-27 – Typical Propane Gas Fuel System; CAUTION! Use only approved components in; Figure 7-28 – LP Gas Carburetion Diagram
Section 7 DIAGNOSTIC TESTS TEST 25 – CHECk FUEL SUPPLY DISCUSSION (GASOLINE MODELS):If the engine cranks but won’t start, don’t overlook the obvious. The fuel supply may be low. Many RV gener- ator installations “share” the fuel tank with the vehicle engine. When such is the case, the Installer may ...
Page 54 - TEST 26 – CHECk WIRE 14 POWER SUPPLY
The greater the airflow through the carburetor venturi, the lower the pressure at the venturi throat. The lower the pressure at the venturi throat, the greater the dia- phragm movement, and the greater the movement of the regulator valve. The more the regulator valve opens, the greater the gas flow ...
Page 55 - TEST 28 – CHECk FUEL SOLENOId
Section 7 DIAGNOSTIC TESTS TEST 27 – CHECk WIRE 18 DISCUSSION:Wire 18 controls sending the STOP signal to the Printed Circuit Board. Coach manufacturers some- times install a 15 to 30 foot remote harness. If unit shuts down or will not start, a possible ground exists on Wire 18. PROCEDURE:1. Disconn...
Page 56 - TEST 29 – CHECk IgNITION SPARk
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 ground wire. 5. If the Fuel Solenoid operates, proceed to Test 29. TEST 29 – CHECk IgNITION SPARk DISCUSSIO...
Page 57 - TEST 30 - CHECk SPARk PLUgS; Figure 7-35 – Setting Spark Plug Gap; TEST 31 – CHECk ANd AdJUST IgNITION
Section 7 DIAGNOSTIC TESTS Figure 7-34. – Cylinder Balance Test 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 SPARk PLUgS DISC...
Page 58 - Figure 7-37. – Setting Ignition Magneto; Figure 7-38. – Engine Ground Harness Test Points
to Step 2. If the unit does not produce spark or has weak spark go to Step 4. 2. Do the following: a. Set a VOM to measure resistance. Connect the positive (+) meter test lead to Wire 18A (Wire 18A still removed from the j1 connec- tor) Connect the negative (-) meter test lead to a clean frame groun...
Page 59 - Note: Before replacing the Ignition Magneto, check; TEST 32 – CHECk VALVE AdJUSTMENT; Intake valve; TORQUE SPECIFICATION; FEELER GAUGE; Figure 7-39 – Adjusting Valve Clearance
Section 7 DIAGNOSTIC 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 defective insulated terminal stud. 4. If sparking still does not occur after adjusting the armature air gap, testing the ground wi...
Page 61 - CHOKE CONTROL ROD; TEST 35 – CHECk ENgINE / CYLINdER LEAk
Section 7 DIAGNOSTIC TESTS in its coil, tighten the two screws. Verify that the choke solenoid plunger and linkage move freely without any drag or resistance that may restrict movement. CHOKE CONTROL ROD CHOKE SOLENOIDMOVES VERTICALLY PLUNGER Figure 7-42. – Choke Solenoid Adjustment 4. Disconnect Co...
Page 62 - TEST 36 – CHECk OIL PRESSURE SWITCH
DISCUSSION:The Cylinder Leak Down Tester checks the sealing (compression) ability of the engine by measuring air leakage from the combustion chamber. Compression loss can present many different symptoms. This test is designed to detect the section of the engine where the fault lies before disassembl...
Page 63 - TEST 37 – CHECk WIRE 86 FOR CONTINUITY
Section 7 DIAGNOSTIC TESTS Figure 7-44. – Oil Pressure Switch PROCEDURE:1. Check engine oil level. If necessary, replenish oil level to the dipstick “FULL” mark. 2. Set a VOM to its “Rx1” scale and zero the meter. 3. Connect the meter test leads across the switch ter minals, with engine shut down. T...
Page 64 - Figure 7-46. – Testing Oil Temperature Switch; TEST 39 – CHECk WIRE 85 FOR CONTINUITY
3. Connect the test leads of a VOM across the switch terminals. The meter should read “Infinity”. 4. H e a t t h e o i l . W h e n o i l t e m p e ra t u r e r e a c h- es approximately 270-284° F., the switch con- tacts should close and the meter should read “Continuity”. Figure 7-46. – Testing Oil...
Page 65 - TEST 41 – CHECk LPg FUEL SOLENOId
Section 7 DIAGNOSTIC TESTS RESULTS:1. If Choke Plate is binding in Step 1, repair or replace binding Choke Plate. If Bi-Metal Heater Assembly tests good, go to Test 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 resis...
Page 67 - ITEM
Section 9 Exploded views Page 65 ITEM QTY. DESCRIPTION 1 1 TRAY, 530 RV 2 2 NUT FLANGE 5/16-18 LOCk 3 8 NUT HEx 5/16-18 STEEL 4 12 WASHER LOCk M8-5/16 5 13 WASHER FLAT 5/16-M8 ZINC 6 2 SCREW HHC 3/8-24 x 1-1/2 G8 7 1 BELT V-RIBBED 4L x 43.75" LG 8 2 WASHER LOCk M10 9 2 WASHER FLAT 3/8-M10 ZINC 1...
Page 68 - Enclosure – Drawing No.
Page 66 Enclosure – Drawing No. 0G3881-C Section 9Exploded views
Page 69 - ITEM QTY. DESCRIPTION
Section 9 Exploded views Page 67 ITEM QTY. DESCRIPTION 1 1 ENCLOSURE DOOR 2 2 SLIDE LATCH, FLUSH 3 1 FOAM ENCLOSURE DOOR 4 23 NUT FLANGE M6-1.0 NYLOk * 26 NUT FLANGE M6-1.0 NYLOk (LP) 5 1 BRACkET, ENCLOSURE ELECTRIC HTR 6 1 GROMMET, OIL FILTER 7 1 U CHANNEL 1/8” 8 1 TRAY, 530 RV 9 1 GASkET AIR IN BO...
Page 70 - Control Panel – Drawing No.; REAR; TO
Page 68 Control Panel – 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 9Explo...
Page 71 - ITEM QTY. DESCRIPTION
Section 9 Exploded views Page 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 FLat 1/4-M6 ZINC 7 1 WaSHEr LOCK SPECIaL 1/4" 8 1 FUEL PUMP MOUNtING BraCKE...
Page 72 - Engine Accessories – Drawing No. 0G7718-B
Page 70 Engine Accessories – Drawing No. 0G7718-B Section 9Exploded views
Page 78 - Major Features and Dimensions – Drawing No. 0G5519-b
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"] A C OUTPUT HARNESS 109. 1 [4 5/16"] 543. 8 [21 7/16"] FR ONT DOOR A CCESS FO R REQUIRED MAINTENANCE 853. 4 [33 5/8"] FUE L INLET BA TTER Y CONNECTION (POSITIVE) 3/8"...
Page 79 - SPECIFICATIONS & CHARTS; NOMINAL RESISTANCES OF gENERATOR WINdINgS AT 68°F
Section 10 SPECIFICATIONS & CHARTS Page 77 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 MA...
Page 80 - Electrical Schematic and Wiring Diagram – Drawing No.
Section 11ELECTRICAL DATA Page 78 Electrical Schematic and Wiring Diagram – Drawing No. 0G4221-B
Page 81 - ELECTRICAL DATA
Section 11 ELECTRICAL DATA Page 79 Electrical Schematic and Wiring Diagram – Drawing No. 0G4221-B
Generac 005793-3
User Manual
Generac 5943-3
User Manual
Generac XG8000E-5747-0
User Manual
Generac GP5500-5939-5
User Manual
Generac 005939-2
User Manual
Generac XG4000-5778-1
User Manual
Generac 005939-6
User Manual
Generac GP6500-5940-0
User Manual
Generac XG7000E-5798-2
User Manual
Generac 006673-0
User Manual
Generac 5939-6
User Manual
Generac 006230-0
User Manual