Generac Power Systems Guardian 5410 Betriebsanleitung

RV 45/55/65

Diagnostic

RepaiR Manual

Diagnostic

RepaiR Manual

RECREATIONAL VEHICLE GENERATOR

MoDels 5410, 5411, 5412,

5413, 5414 & 5415

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 FOUND SPECIAL INSTRUCTIONS WHICH, IF NOT COMPLIED

WITH, COULD RESULT IN PERSONAL INJURY OR DEATH.

*CAUTION! Under this heading will be found special instructions which, if not complied with, could result

in damage to equipment and/or property.

These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance with these special

Instructions plus “common sense” are major accident prevention measures.

NOTICE TO USERS OF THIS MANUAL

This SERVICE MANUAL has been written and published by Generac to aid our dealers’ mechanics and com-

pany service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures for these products, or like or

similar products manufactured and marketed by Generac. That they have been trained in the recommended

servicing procedures for these products, including the use of common hand tools and any special Generac

tools or tools from other suppliers.

Generac could not possibly know of and advise the service trade of all conceivable procedures by which a

service might be performed and of the possible hazards and/or results of each method. We have not under-

taken any such wide evaluation. Therefore, anyone who uses a procedure or tool not recommended by

Generac must first satisfy himself that neither his nor the products safety will be endangered by the service

procedure selected.

All information, illustrations and specifications in this manual are based on the latest product information

available at the time of publication.

When working on these products, remember that the electrical system and engine ignition system are capa-

ble of violent and damaging short circuits or severe electrical shocks. If you intend to perform work where

electrical terminals could be grounded or touched, the battery cables should be disconnected at the battery.

Any time the intake or exhaust openings of the engine are exposed during service, they should be covered to

prevent accidental entry of foreign material. Entry of such materials will result in extensive damage when the

engine Is started.

During any maintenance procedure, replacement fasteners must have the same measurements and

strength as the fasteners that were removed. Metric bolts and nuts have numbers that indicate their strength.

Customary bolts use radial lines to indicate strength while most customary nuts do not have strength mark-

ings. Mismatched or incorrect fasteners can cause damage, malfunction and possible injury.

REPLACEMENT PARTS

Components on Generac recreational vehicle generators are designed and manufactured to comply with

Recreational Vehicle Industry Association (RVIA) Rules and Regulations to minimize the risk of fire or explo-

sion. The use of replacement parts that are not in compliance with such Rules and Regulations could result

in a fire or explosion hazard. When servicing this equipment, It is extremely important that all components be

properly installed and tightened. If Improperly Installed and tightened, sparks could Ignite fuel vapors from

fuel system leaks.

Table of Contents

Page 1

SAFETY ........................... INSIDE FRONT COVER

SECTION 1:

GENERATOR FUNDAMENTALS ....................... 3-7

MAGNETISM ................................................................ 3

ELECTROMAGNETIC FIELDS .................................... 3

ELECTROMAGNETIC INDUCTION ............................. 3

A SIMPLE AC GENERATOR ........................................ 4

A MORE SOPHISTICATED AC GENERATOR ............. 4

FIELD BOOST .............................................................. 6

GENERATOR AC CONNECTION SYSTEM ................. 6

SECTION 2:

MAJOR GENERATOR COMPONENTS ............ 8-11

ROTOR ASSEMBLY ...................................................... 8

STATOR ASSEMBLY ..................................................... 8

BRUSH HOLDER ......................................................... 9

EXCITATION CIRCUIT COMPONENTS ....................... 9

CRANKCASE BREATHER ......................................... 10

CONTROL PANEL COMPONENT IDENTIFICATION . 11

SECTION 3:

INSULATION RESISTANCE TESTS .............. 12-14

EFFECTS OF DIRT AND MOISTURE ........................ 12

INSULATION RESISTANCE TESTERS ...................... 12

DRYING THE GENERATOR ....................................... 12

CLEANING THE GENERATOR .................................. 12

STATOR INSULATION RESISTANCE ......................... 13

TESTING ROTOR INSULATION ................................ 14

THE MEGOHMMETER .............................................. 14

SECTION 4:

MEASURING ELECTRICITY ......................... 15-17

METERS ..................................................................... 15

THE VOM .................................................................... 15

MEASURING AC VOLTAGE ....................................... 15

MEASURING DC VOLTAGE ....................................... 15

MEASURING AC FREQUENCY ................................. 15

MEASURING CURRENT ........................................... 16

MEASURING RESISTANCE ...................................... 16

ELECTRICAL UNITS .................................................. 17

OHM’S LAW ................................................................ 17

SECTION 5:

ENGINE DC CONTROL SYSTEM ................. 18-26

INTRODUCTION ........................................................ 18

OPERATIONAL ANALYSIS .................................... 18-21

PRINTED CIRCUIT BOARD ....................................... 22

BATTERY .................................................................... 22

7.5 AMP FUSE ........................................................... 23

START-STOP SWITCH ............................................... 23

STARTER CONTACTOR RELAY

& STARTER MOTOR ................................................. 24

SECTION 6:

TROUBLESHOOTING FLOWCHARTS .................. 25-34

IF PROBLEM INVOLVES AC OUTPUT ...................... 25

PROBLEM 1 –

VOLTAGE & FREQUENCY ARE BOTH

HIGH OR LOW ........................................................... 25

PROBLEM 2 –

GENERATOR PRODUCES ZERO VOLTAGE OR

RESIDUAL VOLTAGE (5-12 VAC) .......................... 26-27

PROBLEM 3 –

EXCESSIVE VOLTAGE/FREQUENCY DROOP

WHEN LOAD IS APPLIED .......................................... 27

PROBLEM 4 –

ENGINE OVERSPEED WARNING CODE

FLASHING ON SW1 LED (4 FLASHES)....................... 28

PROBLEM 5 –

PRIMING FUNCTION DOES NOT WORK

(GASOLINE MODELS) ............................................... 28

PROBLEM 6 –

ENGINE WILL NOT CRANK ....................................... 29

PROBLEM 7 –

ENGINE CRANKS BUT WILL NOT START

(GASOLINE UNITS) ................................................... 30

PROBLEM 7 –

ENGINE CRANKS BUT WILL NOT START

(LP UNITS) ................................................................. 31

PROBLEM 8 –

ENGINE STARTS HARD AND RUNS ROUGH

(GASOLINE UNITS) ................................................... 32

PROBLEM 8 –

ENGINE STARTS HARD AND RUNS ROUGH

(LP UNITS) ................................................................. 33

PROBLEM 9 –

HIGH OIL TEMPERATURE FAULT (6 FLASHES)

OR LOW OIL PRESSURE FAULT (5 FLASHES) ....... 34

PROBLEM 10 –

7.5 AMP (F1) FUSE BLOWING .................................. 35

SECTION 7:

DIAGNOSTIC TESTS ...................................... 36-63

INTRODUCTION ........................................................ 36

TEST 1 –

Check No-Load Voltage And Frequency...................... 36

TEST 2 –

Check Stepper Motor Control ...................................... 36

TEST 4 –

Fixed Excitation Test/Rotor Amp Draw ........................ 37

TEST 5 –

Check Field Boost........................................................ 39

TEST 6 –

Test Stator DPE Winding ............................................. 39

TEST 7 –

Check Sensing Leads/Power Windings ...................... 40

TEST 8 –

Check Brush Leads ..................................................... 41

TEST 9 –

Check Brushes & Slip Rings........................................ 42

TEST 10 –

Check Rotor Assembly ................................................ 42

TEST 11 –

Check Main Circuit Breaker ......................................... 43

TEST 12 –

Check Load Voltage & Frequency................................ 43

TEST 13 –

Check Load Watts & Amperage................................... 43

TEST 14 –

Try Cranking the Engine .............................................. 44

TEST 15 –

Check Fuel Pump ........................................................ 44

TEST 16 –

Check 7.5 Amp Fuse ................................................... 45

TEST 17 –

Check Battery & Cables............................................... 45

TEST 18 –

Check Power Supply to Printed Circuit Board.............. 45

Test 19 –

Check Continuity of Wire 17 .......................................... 46

TEST 20 –

Check Start-Stop Switch.............................................. 46

TEST 21 –

Check Power Supply to Wire 56................................... 47

TEST 22 –

Check Starter Contactor Relay .................................... 47

TEST 23 –

Check Starter Contactor ............................................. 48

TEST 24 –

Check Starter Motor .................................................... 48

TEST 25 –

Check Fuel Supply....................................................... 51

TEST 26 –

Check Wire 14 Power Supply....................................... 52

TEST 27 –

Check Wire 18 ............................................................. 53

TEST 28 –

Check Fuel Solenoid

(Gasoline Models) ....................................................... 53

TEST 29 –

Check Ignition Spark.................................................... 54

TEST 30 –

Check Spark Plugs ...................................................... 55

TEST 31 –

Check and Adjust Ignition Magnetos .......................... 55

TEST 32 –

Check Valve Adjustment ............................................. 57

TEST 33 –

Check Carburetion ...................................................... 58

TEST 34 –

Check Choke Solenoid ................................................ 58

TEST 35 –

Check Engine / Cylinder Leak Down Test /

Compression Test ........................................................ 59

TEST 36 –

Check Oil Pressure Switch .......................................... 60

TEST 37 –

Test Wire 86 for Continuity............................................. 61

TEST 38 –

Test Oil Temperature Switch ........................................ 61

TEST 39 –

Test Wire 85 for Continuity............................................. 62

TEST 40 –

Test Choke Heater ...................................................... 62

TEST 41 –

Check LPG Fuel Solenoid............................................ 63

SECTION 8:

EXPLODED VIEWS / PART NUMBERS......... 64-83

BASE & PULLEY DRAWING ...................................... 64

ENCLOSURE DRAWING ........................................... 66

CONTROL PANEL DRAWING..................................... 68

ENGINE ACCESSORIES DRAWING ............................ 70

530 RV ENGINE DRAWING ....................................... 72

ROTOR AND STATOR DRAWING .............................. 74

SECTION 9:

SPECIFICATIONS & CHARTS ....................... 76-86

MAJOR FEATURES AND DIMENSIONS ................... 76

GENERATOR SPECIFICATIONS ............................... 77

NOMINAL RESISTANCES OF

GENERATOR WINDINGS AT 68°F ............................. 77

TORQUE REQUIREMENTS........................................ 77

SECTION 10:

ELECTRICAL DATA........................................ 78-79

ELECTRICAL SCHEMATIC AND

WIRING DIAGRAM ..................................................... 78

Page 2

Table of Contents

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 patterns has led to the development of gen-

erators, motors and numerous other devices that uti-

lize magnetism to produce and use electrical energy.

See Figure 1-1. The space surrounding a magnet is

permeated by magnetic lines of force called “flux”.

These lines of force are concentrated at the magnet’s

north and south poles. They are directed away from

the magnet at its north pole, travel in a loop and re-

enter the magnet at its south pole. The lines of force

form definite patterns which vary in intensity depend-

ing on the strength of the magnet. The lines of force

never cross one another. The area surrounding a

magnet in which its lines of force are effective is called

a “magnetic field”.

Like poles of a magnet repel each other, while unlike

poles attract each other.

Figure 1-1. – Magnetic Lines of Force

ELECTROMAGNETIC FIELDS

All conductors through which an electric current is

flowing have a magnetic field surrounding them. This

field is always at right angles to the conductor. If a

compass is placed near the conductor, the compass

needle will move to a right angle with the conductor.

The following rules apply:

•

The greater the current flow through the conductor,

the stronger the magnetic field around the conductor.

• The increase in the number of lines of force is

directly proportional to the increase in current flow

and the field is distributed along the full length of

the conductor.

• Thedirectionofthelinesofforcearoundaconduc-

tor can be determined by what is called the “right

hand rule”. To apply this rule, place your right hand

around the conductor with the thumb pointing in

the direction of current flow. The fingers will then be

pointing in the direction of the lines of force.

NOTE: The “right hand rule” is based on the “cur-

rent flow” theory which assumes that current

flows from positive to negative. This is opposite

the “electron” theory, which states that current

flows from negative to positive.

Figure 1-2. – The Right Hand Rule

ELECTROMAGNETIC INDUCTION

An electromotive force (EMF) or voltage can be pro-

duced in a conductor by moving the conductor so that

it cuts across the lines of force of a magnetic field.

Similarly, if the magnetic lines of force are moved so

that they cut across a conductor, an EMF (voltage)

will be produced in the conductor. This is the basic

principal of the revolving field generator.

Figure 1-3, below, illustrates a simple revolving field

generator. The magnetic field (Rotor) is rotated so that

its lines of magnetic force cut across a coil of wires

called a Stator. A voltage is then induced into the

Stator windings. If the Stator circuit is completed by

connecting a load (such as a light bulb), current will

flow in the circuit and the bulb will light.

LOAD

ROTOR

STATOR

Figure 1-3. – A Simple Revolving Field Generator

Page 3

Section 1

GENERATOR 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 magnetic

pole.

As the ROTOR turns, its magnetic field cuts across

the stationary STATOR. A voltage is induced Into

the STATOR windings. When the magnet’s NORTH

pole passes the STATOR, current flows in one direc-

tion. Current flows in the opposite direction when the

magnet’s SOUTH pole passes the STATOR. This con-

stant reversal of current flow results in an alternating

current (AC) waveform that can be diagrammed as

shown in Figure 1-5.

The ROTOR may be a 2-pole type having a single

NORTH and a single SOUTH magnetic pole. Some

ROTORS are 4-pole type with two SOUTH and two

NORTH magnetic poles. The following apply:

1. The 2-pole ROTOR must be turned at 3600 rpm

to produce an AC frequency of 60 Hertz, or at

3000 rpm to deliver an AC frequency of 50 Hertz.

2. The 4-pole ROTOR must operate at 1800 rpm to

deliver a 60 Hertz AC frequency or at 1500 rpm to

deliver a 50 Hertz AC frequency.

TAT

NETI

FIEL

Figure 1-4. – A Simple AC Generator

CURRENT VOLTAGE

ONE CYCLE

0180 360

(+)

(-)

Figure 1-5. – Alternating Current Sine Wave

A MORE SOPHISTICATED AC GENERATOR

Figure 1-6 represents a more sophisticated generator.

A regulated direct current is delivered into the ROTOR

windings via carbon BRUSHES AND SLIP RINGS.

This results in the creation of a regulated magnetic

field around the ROTOR. As a result, a regulated volt-

age is induced into the STATOR. Regulated current

delivered to the ROTOR is called “EXCITATION” cur-

rent.

TAT

RIN

RRENT

TAT

Figure 1-6. – A More Sophisticated Generator

See Figure 1-7 (next page). The revolving magnet-

ic field (ROTOR) is driven by the engine at a con-

stant speed. This constant speed is maintained by a

mechanical engine governor. Units with a 2-pole rotor

require an operating speed of 3600 rpm to deliver

a 60 Hertz AC output. Engine governors are set to

maintain approximately 3720 rpm when no electrical

loads are connected to the generator.

Page 4

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” magnetism is normally present in

the Rotor and is sufficient to induce approximately

7 to 12 volts AC Into the STATOR’s AC power

windings.

2. During startup, a Printed Circuit Board (PCB)

delivers battery voltage to the ROTOR, via the

brushes and slip rings.

a. The battery voltage is called “Field Boost”.

b. Flow of direct current through the ROTOR

increases the strength of the magnetic field

above that of “residual” magnetism alone.

3. “Residual” plus “Field Boost” magnetism induces

a voltage into the Stator excitation (DPE) and AC

Power windings.

4. Excitation winding unregulated AC output is deliv-

ered to an electronic voltage regulator, via an

excitation circuit breaker.

a. A “Reference” voltage has been preset into

the Voltage Regulator.

b. An “Actual” (“sensing”) voltage is delivered to

the Voltage Regulator via sensing leads from

the Stator AC power windings.

c. The Regulator “compares” the actual (sens-

ing) voltage to its pre-set reference voltage.

(1) If the actual (sensing) voltage is great-

er than the pre-set reference voltage, the

Regulator will decrease the regulated current

flow to the Rotor.

(2) If the actual (sensing) voltage is less than

the pre-set reference voltage, the Regulator

will increase the regulated current flow to the

Rotor.

(3) In the manner described, the Regulator

maintains an actual (sensing) voltage that is

equal to the pre-set reference voltage.

NOTE: The Voltage Regulator also changes the

Stator excitation windings alternating current (AC)

output to direct current (DC).

5. When an electrical load is connected across the

Stator power windings, the circuit is completed

and an electrical current will flow.

6. The Rotor’s magnetic field also induces a voltage

into the Stator battery charge windings.

Page 5

Figure 1-7. – Generator Operating Diagram

Section 1

GENERATOR 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 Printed Circuit Board,

then to the Rotor via brushes and slip rings. This is

called “Field Boost” voltage.

Field boost voltage is delivered to the Rotor only while

the engine is cranking. The effect is to “flash the field”

every time the engine is cranked. Field boost voltage

helps ensure that sufficient “pickup” voltage is avail-

able on every startup to turn the Voltage Regulator on

and build AC output voltage.

NOTE: Loss of the Field Boost function may or

may not result in loss of AC power winding output.

If Rotor residual magnetism alone is sufficient to

turn the Regulator on, loss of Field Boost may go

unnoticed. However, if residual magnetism alone

is not enough to turn the Regulator on, loss of the

Field Boost function will result in loss of AC power

winding output to the load. The AC output voltage

will then drop to a value commensurate with the

Rotor’s residual magnetism (about 7-12 VAC).

GENERATOR AC CONNECTION SYSTEM

These air-cooled generator sets are equipped with

dual stator AC power windings. These two stator wind-

ings supply electrical power to customer electrical

loads by means of a dual 2-wire connection system.

Generators may be installed to provide the following

outputs:

1. 120 VAC loads only — one load with a maximum

total wattage requirement equal to the generator’s

rated power output (in watts), and 120 VAC across

the generator output terminals. Figure 1-8, page

7, shows the generator lead wire connections for

120 VAC ONLY.

2. 120/240 VAC loads — one load with a maximum

total wattage requirement equal to the generator’s

rated power output, and 240 VAC across the gen-

erator output terminals; or two separate loads,

each with a maximum total wattage requirement

equal to half of the generator’s rated power out-

put (in watts), and 120 VAC across the generator

output terminals. Figure 1-9 on page 7, shows the

generator lead wire connections for 120/240 VAC

loads.

You can use your generator set to supply electrical

power for operating one of the following electrical

loads:

• RV 45G & LP: 120 and/or 240 volts, single phase,

60 Hz electrical loads. These loads can require up

to 4500 watts (4.5 kW) of total power, but cannot

exceed 45.8 AC amperes of current at 120 volts or

exceed 22.9 AC amperes at 240 volts.

• RV 55G & LP: 120 and/or 240 volts, single phase,

60 Hz electrical loads. These loads can require up

to 5500 watts (5.5 kW) of total power, but cannot

exceed 54.1 AC amperes of current at 120 volts or

exceed 27 AC amperes at 240 volts.

• RV 65G & LP: 120 and/or 240 volts, single phase,

60 Hz electrical loads. These loads can require up

to 6500 watts (6.5 kW) of total power, but cannot

exceed 62.5 AC amperes of current at 120 volts or

exceed 31.2 AC amperes at 240 volts.

*Caution! Do not overload the generator. Some

installations may require that electrical loads

be alternated to avoid overloading. Applying

excessively high electrical loads may damage

the generator and may shorten its life. Add up

the rated watts of all electrical lighting, appli-

ance, tool and motor loads the generator will

power at one time. This total should not be

greater than the wattage capacity of the gen-

erator. If an electrical device nameplate gives

only volts and amps, multiply volts times

amps to obtain watts (volts x amps = watts).

Some electric motors require more watts of

power (or amps of current) for starting than

for continuous operation.

LINE BREAKERS (120 VOLTS ONLY):

Protects generator’s AC output circuit against

overload, i.e., prevents unit from exceeding wattage/

amperage capacity. The circuit breaker ratings are as

follows:

Model Cir. Breaker 1 Cir. Breaker 2 240 Volt

RV 45 20A 20A 20A 2P

RV 55 20A 30A 25A 2P

RV 65 30A 30A 30A 2P

Page 6

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).

For dual voltage output, the “Neutral” line remains

grounded.

NOTE: For units with two 20 amp or two 30 amp

main breakers, the existing breakers may be re-

used when reconnecting for dual voltage output.

However, on units with a 30 amp and a 20 amp

main breaker, you may wish to install a 2-pole

breaker that is rated closer to the unit’s rated

capacity (use two 25 amp main breakers).

RED

WHITE

BLACK

GROUNDED NEUTRAL

STATOR WINDINGS

CB1

CB2

Figure 1-9 - Connection for 120/240 Volts

NOTE: If this generator has been reconnected

for dual voltage AC output (120/240 volts), the

replacement line breakers should consist of

two separate breakers with a connecting piece

between the breaker handles (so that both break-

ers operate at the same time). If the unit is recon-

nected for dual voltage, it is no longer RVIA listed.

Page 7

Section 2

MAJOR GENERATOR COMPONENTS

ROTOR ASSEMBLY

The Rotor is sometimes called the “revolving field”,

since it provides the magnetic field that induces a

voltage into the stationary Stator windings. Slip rings

on the Rotor shaft allow excitation current from the

voltage regulator to be delivered to the Rotor wind-

ings. The Rotor is driven by the engine at a constant

speed through a pulley and belt arrangement.

All generator models in this manual utilize a 2-pole

Rotor, i.e., one having a single north and a single

south pole. This type of Rotor must be driven at 3600

rpm for a 60 Hertz AC output, or at 3000 rpm for a 50

Hertz output.

Slip rings may be cleaned. If dull or tarnished, clean them

with fine sandpaper (a 400 grit wet sandpaper is recom-

mended). DO NOT USE ANY MATERIAL CONTAINING

METALLIC GRIT TO CLEAN SLIP RINGS.

STATOR ASSEMBLY

The Stator is “sandwiched” between the upper and

lower bearing carriers and retained in that position by

four Stator studs. A total of eight (8) leads are brought

out of the Stator as follows:

1. Four (4) Stator power winding output leads (Wires

No. 11, 22, 33 and 44). These leads deliver power

to connected electrical loads.

2. Stator power winding “sensing” leads (11S and

22S). These leads deliver an “actual voltage sig-

nal to the electronic Voltage Regulator.

3. Two excitation winding output leads (No. 2 and 6).

These leads deliver unregulated excitation current

to the voltage regulator.

Page 8

Figure 2-1. Exploded View of Generator

1. BRUSH HOLDER

2. UPPER BEARING CARRIER

3. STATOR

4. ROTOR

5. LOWER BEARING CARRIER

6. ENGINE

7. PULLEYS AND BELT

8. FANS

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