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Generac Power Systems Guardian 5410, Repair Manual

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Generac Power Systems Guardian 5410 Repair Manual Download Page 36

Section 6
TROUBLESHOOTING 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 

CONTINUITY

GOOD

GOOD

BAD

BAD

REPLENISH OIL

OIL LEVEL LOW

OIL LEVEL O.K.

REPLACE 

PRINTED CIRCUIT 

BOARD

REPLACE SWITCH

BAD

REPLENISH OIL

OIL LEVEL LOW

REPAIR OR REPLACE

LOW OIL 

PRESSURE – 

5 FLASHES 

ON SW1 LED

TEST 36 – CHECK 

OIL PRESSURE  

SWITCH 

TEST 25 – 

CHECK FUEL 

SUPPLY

GOOD

GOOD

GOOD

GOOD

BAD

REPLENISH FUEL

NO FUEL

CHECK 

ENGINE OIL 

LEVEL

REPLACE 

PRINTED CIRCUIT 

BOARD

TEST 37 – CHECK 

WIRE 86 FOR 

CONTINUITY

Summary of Contents for Guardian 5410

Page 1: ...RV 45 55 65 Diagnostic Repair Manual Diagnostic Repair Manual RECREATIONAL VEHICLE GENERATOR ModelS 5410 5411 5412 5413 5414 5415...

Page 2: ...st 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...

Page 3: ...mp 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...

Page 4: ...t 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 Lea...

Page 5: ...rrent 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 fiel...

Page 6: ...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 STATOR ROTOR MAGNETIC FIELD Figu...

Page 7: ...ia 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...

Page 8: ...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...

Page 9: ...cting 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 br...

Page 10: ...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 b...

Page 11: ...1S BA DPE WINDING 6 2 4 0 FIELD 0 Figure 2 5 Schematic Excitation Circuit VOLTAGE REGULATOR Six 6 leads are connected to the voltage regulator as follows Two 2 SENSING leads deliver ACTUAL AC output v...

Page 12: ...ltage should be about 124 volts Crankcase Breather CRANKCASE BREATHER GASKET SCREEN OIL VAPOR COLLECTOR Figure 2 8 Crankcase Breather DESCRIPTION The crankcase breather is equipped with a reed valve t...

Page 13: ...R 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 BREAKERS CB1 CB2 ENGINE CON...

Page 14: ...of Hi Pot Tester DANGER INSULATION RESISTANCE TESTERS SUCH AS HI POT TESTERS AND MEGOHMMETERS ARE A SOURCE OF HIGH AND DANGEROUS ELECTRICAL VOLTAGE FOLLOW THE TESTER MANUFACTURER S INSTRUCTIONS CAREFU...

Page 15: ...D TESTS See Figure 3 2 To test the Stator for a short to ground condition proceed as follows 1 Disconnect and Isolate all Stator leads as follows a Disconnect sensing leads 11S and 22S from the voltag...

Page 16: ...l Stator leads Figure 3 2 and connect all of the Stator leads together FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY Use a megger power setting of 1500 volts Connect one megger test lead to...

Page 17: ...r s AC output voltage only at the unit s rated operating speed and AC frequency 2 The generator s voltage regulator can be adjusted for correct output voltage only while the unit is operating at its c...

Page 18: ...A Line Splitter NOTE If the physical size of the conductor or ammeter capacity does not permit all lines to be measured simultaneously measure current flow in each individual line Then add the Individ...

Page 19: ...n point OHM Unit measuring resistance or opposition to flow vOLT Unit measuring force or difference in potential causing current flow Conductor of a Circuit Figure 4 4 Electrical Units OHM The OHM is...

Page 20: ...33 DPE WINDING 6 2 4 0 44 CB2 CB1 FIELD BLACK RED 18 17 0 56 712 0 18 11S 22S 13 16 0 17 REMOTE PANEL CONNECTOR 14 712 D E G F C B 18 17 H A 0 GREEN WHITE 0 13 712 14 0 GREEN WHITE 0 NEUTRAL CONNECTIO...

Page 21: ...0 18A 4 15 11S 0 14 0 241 FS 14 712 22 44 44 22 22S 22 0 0 0 CIRCUIT CONDITION CRANKING When the START STOP SWITCH SW1 or REMOTE PANEL START SWITCH is momentarily held in the START position and then...

Page 22: ...VOLTAGE 2 2 0 6 22S 4 11S 6 0 4 22S 11S LED 0 712 CH CS 0 90 14 RED BLACK SM SC BATTERY 12V SC 0 0 16 16 0 13 POWER WINDINGS 11 BA 33 DPE WINDING 6 2 4 0 44 CB2 CB1 FIELD BLACK RED 18 17 0 56 712 0 18...

Page 23: ...NNECTION CUSTOMER BY CUSTOMER 18 15 17 712 86 90 14 85 56 0 18A 4 15 11S 0 14 0 241 FS 14 712 22 44 44 22 22S 22 0 0 0 CIRCUIT CONDITION SHUTDOWN Setting the START STOP SWITCH SW1 or the REMOTE PANEL...

Page 24: ...own 8 712 PCB control Alarm led 9 56 Delivers 12 VDC to Starter Contactor SC cranking only 10 90 To Choke Solenoid When grounded by the PCB the choke operates at two sec onds ON two second OFF interva...

Page 25: ...170 25 CHARGING A BATTERY Use an automotive type battery charger to recharge a battery Battery fluid is an extremely corrosive sulfuric acid solution that can cause severe burns For that reason the f...

Page 26: ...1 2 3 7 4 5 6 712 712 18 18 17 0 0 JUMPER WIRE Figure 5 5 Start Stop Switch Starter Contactor Relay Starter Motor The positive battery cable attaches to the large lug on the starter contactor Wire 13...

Page 27: ...IGH OR LOW FREQUENCY GOOD VOLTAGE HIGH OR VOLTAGE LOW FREQUENCY GOOD ZERO OR RESIDUAL VOLTAGE NO LOAD VOLTAGE FREQUENCY GOOD TEST 1 CHECK NO LOAD VOLTAGE FREQUENCY GO TO PROBLEM 1 GO TO VOLTAGE REGULA...

Page 28: ...tage or Residual Voltage 5 12VAC RESET TO ON OR REPLACE IF BAD TEST 11 CHECK MAIN CIRCUIT BREAKER TEST 5 CHECK FIELD BOOST TEST 6 TEST STATOR DPE WINDING TEST 8 CHECK BRUSH LEADS TEST 9 CHECK BRUSHES...

Page 29: ...TATOR 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...

Page 30: ...15 CHECK FUEL PUMP OPERATION TEST 14 TRY CRANKING THE ENGINE TEST 20 CHECK START STOP SWITCH SW1 BAD BAD GOOD GOOD REPLACE PRINTED CIRCUIT BOARD BAD Problem 4 Engine Overspeed Warning Code Flashing on...

Page 31: ...HECk FOR MECHANICAL BINDING OF THE ENGINE OR ROTOR Problem 6 Engine Will Not Crank TEST 16 CHECk 7 5 AMP FUSE TEST 17 CHECk BATTERY CABLES CHECk SW1 LED FOR LOW BATTERY WARNING 2 FLASHES BAD BAD FUSE...

Page 32: ...BAD BAD GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD TEST 26 CHECK WIRE 14 POWER SUPPLY TEST 20 CHECK START STOP SWITCH TEST 25 CHECK FUEL SUPPLY TEST 15 CHECK FUEL PUMP OPERATION TEST 28 CHECK FUEL...

Page 33: ...S NECESSARY BAD BAD BAD GOOD GOOD GOOD GOOD GOOD GOOD TEST 26 CHECK WIRE 14 POWER SUPPLY TEST 20 CHECK START STOP SWITCH TEST 25 CHECK FUEL SUPPLY TEST 41 CHECK LPG FUEL SOLENOID TEST 29 CHECK IGNITIO...

Page 34: ...PARENT TEST 29 CHECK IGNITION SPARK TEST 30 CHECK SPARK PLUGS CLEAN AND REGAP OR REPLACE SPARK PLUG ENGINE RUNS O K NOW STOP TESTS REPAIR OR REPLACE AS NECESSARY REPAIR OR REPLACE ADJUST VALVES REPLEN...

Page 35: ...NGINE MISS IS APPARENT TEST 29 CHECK IGNITION SPARK TEST 30 CHECK SPARK PLUGS CLEAN AND REGAP OR REPLACE SPARK PLUG REPAIR OR REPLACE AS NECESSARY CHECK FUEL REGULATOR AND CARBURETOR ADJUST VALVES REP...

Page 36: ...ENGINE OIL LEVEL TEST 39 CHECK WIRE 85 FOR CONTINUITY GOOD GOOD BAD BAD REPLENISH OIL OIL LEVEL LOW OIL LEVEL O K REPLACE PRINTED CIRCUIT BOARD REPLACE SWITCH BAD REPLENISH OIL OIL LEVEL LOW REPAIR O...

Page 37: ...MEASURED TO GROUND THAT COMPONENT OR WIRE IS SHORTED ALSO REFER TO THE INDIVIDUAL TESTS FOR EACH COMPONENT IN SECTION 7 UNDER PROCEDURE SHORT TO GROUND NOTE A Disconnect harness from engine controller...

Page 38: ...and warm up 4 Read the AC voltage 5 Connect an AC frequency meter across AC output leads T1 Red and T2 White Repeat the above procedure RESULTS For units rated 60 Hertz no load voltage and fre quency...

Page 39: ...proximately 10 ohms should be measured e Connect one meter lead to Red connect the remaining test to the stepper motor case No resistance should be measured Infinity or Open RESULTS 1 If the stepper m...

Page 40: ...and connect one meter test lead to that wire Disconnect Wire 22S from the Voltage Regulator and connect the other meter test lead to that wire See Figure 7 5 Start the generator and mea sure the AC v...

Page 41: ...the Voltage Regulator on and build AC output voltage Loss of the field boost function may or may not result in a problem with AC output voltage If the Rotor s residual magnetism is sufficient to turn...

Page 42: ...he Stator assembly 2 If the excitation windings are good perform Insulation Resistance Test page 13 Test 7 Check Sensing Leads Power Windings DISCUSSION The Voltage Regulator regulates excitation curr...

Page 43: ...t leads across Stator leads Wire 33 and Wire 2 The reading should be Infinity RESULTS 1 If the Stator passes all steps except Step 7 repair re connect or replace Sensing leads 11S and 22S 2 Replace th...

Page 44: ...ushes and rings are good go to Test 10 Test 10 Check Rotor Assembly DISCUSSION During the Test 4 Fixed Excitation Test if AC out put voltage did not come up to about one half rated volts one possible...

Page 45: ...enerator the load voltage and frequency should be checked PROCEDURE Perform this test in the same manner as Test 1 but apply a load to the generator equal to its rated capac ity With load applied chec...

Page 46: ...ll test the ground wire Disconnect Connector 2 at the Fuel Pump Set the VOM to measure resistance Connect one test lead to the Black wire Pin 2 of Connector 2 that goes to the Control Panel see Figure...

Page 47: ...ne will not crank go to Test 18 Test 18 Check Power Supply to Printed Circuit Board DISCUSSION If battery voltage is not available to the Printed Circuit Board PCB engine cranking and running will not...

Page 48: ...Stop Switch to START Engine shutdown occurs when Wire 18 from the PCB is connected to frame ground by the Start Stop Switch A defective Start Stop Switch can result in a failure to crank when the swi...

Page 49: ...5 Connect the VOM positive test lead to Wire 56 Pin Location J1 9 at the Printed Circuit Board Connect the other test lead to frame ground 6 Actuate the Start Stop Switch to the START position The met...

Page 50: ...defective or badly corroded Set the VOM to measure DC voltage Connect the positive meter test lead to the Starter Contactor stud that the battery cable is connected to Connect the negative meter test...

Page 51: ...ied to engage pinion engaged but engine did not crank check for mechanical bind ing of the engine or rotor If engine turns over slightly go to Test 32 Check and Adjust Valves NOTE If a starting proble...

Page 52: ...for mance Assemble starter to test bracket and clamp test bracket in vise Figure 7 26 Testing Starter Motor 1 A fully charged 12 volt battery is required 2 Connect jumper cables and clamp on ammeter a...

Page 53: ...NOT exceed 14 inches water col umn The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommen...

Page 54: ...P BRASS HOSE FITTING FUEL HOSE Figure 7 29 Fuel Regulator RESULTS 1 If the LP gas pressure is less than 11 14 inches water column the fuel supply system must be corrected in order to maintain 11 14 in...

Page 55: ...2 Remove air filter cover Disconnect Connector 2 which connects to the fuel pump 3 Activate the Start Stop Switch SW1 to the Start position and hold This will activate the fuel solenoid The fuel solen...

Page 56: ...spark jumps the tester gap intermittently the problem may be in the Ignition Magneto Proceed to Test 31 SPARk TESTER CLAMP CONNECTED TO SPARk PLUG SPARk TESTER SPARk PLUG BOOT Figure 7 33 Checking Eng...

Page 57: ...liver the resulting high voltage across the spark plug gap The ignition magneto houses a solid state circuit board that controls ignition timing Timing is fixed and spark advance is automatic Major co...

Page 58: ...laminations Figure 7 37 Setting Ignition Magneto Armature Air Gap 6 Loosen the mounting screws and let the magnet pull the magneto down against the thickness gauge 7 Tighten both mounting screws 8 To...

Page 59: ...adjusted correctly in order to pro vide the proper air fuel mixture to the combustion chamber Adjusting Valve Clearance Adjust valve clearance with the engine at room tem perature The piston should be...

Page 60: ...eassemble Shelf life on gasoline is 30 days Proper procedures need to be taken for carburetors so that the fuel doesn t varnish over time A fuel stabilizer must be used at all times in order to ensure...

Page 61: ...to measure resistance Disconnect Connector 3 Connect one meter test lead to Wire 90 Connector 3 Pin 2 going to the Choke Solenoid Connect the other meter test lead to Wire 0 Connector 3 Pin 1 Approxim...

Page 62: ...ne Testing has proven that an accurate compression indication can be obtained using the following method PROCEDURE 1 Remove both spark plugs 2 Insert a compression gauge into either cylinder 3 Crank t...

Page 63: ...Disconnect the J1 Connector from the Printed Circuit Board 2 Locate Pin Location J1 6 on the harness end of the J1 Connector 3 Remove Wire 86 from the Low Oil Pressure switch LOP 4 Set a VOM to its R...

Page 64: ...the Choke Plate to fully open Power for the heater element is supplied from Wire 14 to assist the Bi Metal Heater Assembly in opening the Choke Plate after starting Failure of the Choke Plate to open...

Page 65: ...easure resistance Disconnect Wire 0 from the LPG Fuel Solenoid Connect one meter test lead to Wire 0 Connect the other test lead to a clean frame ground Continuity should be mea sured Reconnect Wire 0...

Page 66: ...Section 9 Exploded Views Page 64 Base Pulley Drawing No 0G7720 B...

Page 67: ...T CARR 5 16 18 X 1 21 1 EDGE TRIM W 3 4 HOLLOW CYL 22 1 BLOWER HOUSING WALL 23 1 GASKET LOWER BLOWER HOUSING ITEM QTY DESCRIPTION 24 1 FRAME GT530 RV MOUNTING 25 1 SPACER SAFETY BOLT 375 I D 26 2 SCRE...

Page 68: ...Page 66 Enclosure Drawing No 0G3881 C Section 9 Exploded Views...

Page 69: ...W 19 2 SCREW HHC M8 1 25X16 G8 8 LP 20 2 WASHER LOCK M8 5 16 LP 21 2 WASHER FLAT 5 16 M8 ZINC LP ITEM QTY DESCRIPTION 22 1 BRACKET 530 RV REGULATOR LP 23 1 FOAM BACK ENCLOSURE ALT SIDE 1 FOAM BACK EN...

Page 70: ...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 5...

Page 71: ...8 18 X 1 2 AB 30 1 CONTROL PANEL COVER 31 1 C PNL FACE ITEM QTY DESCRIPTION 32 4 SCREW PPHM 6 32 X 1 4 SEMS 33 1 FUSE 7 5AXBK AGC7 5NX 34 1 HOLDER FUSE 35 1 SWITCH RKRSPDT ON OFF ON ILLUM 36 4 NUT HEX...

Page 72: ...Page 70 Engine Accessories Drawing No 0G7718 B Section 9 Exploded Views...

Page 73: ...SY CAP AND DIPSTICK 45 1 OIL DRAIN DIPSTICK TUBE 46 1 90 DEGREE ELBOW 3 8 NPT X 3 8 BARBED 47 2 HOSE OETIKER CLAMP 48 8 HOSE 3 8 I D ITEM QTY DESCRIPTION 49 1 ASSY OIL DRAIN FITTING 50 1 OIL FILTER SU...

Page 74: ...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...

Page 75: ...LL 23 8 SCREW HHFC M6 1 0 X 25 24 2 GASKET VALVE COVER 25 2 SPARK PLUG 26 12 SCREW HHC M8 1 25 X 56 27 4 WASHER VALVE SPRING 28 2 SEAL VALVE STEM ITEM QTY DESCRIPTION 29 4 VALVE SPRING 30 4 VALVE RETA...

Page 76: ...Page 74 Rotor Stator Drawing No 0G3953 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...

Page 77: ...6 WASHER FLAT 5 16 M8 ZINC 9 4 STUD 530 RV STATOR 10 2 TENSION SPRING 11 2 WASHER SPRING CENTR 12 1 LOWER BEARING CARRIER 13 1 ROTOR 14 1 STATOR 15 1 UPPER BEARING CARRIER 16 4 WASHER LOCK M8 5 16 17...

Page 78: ...QUIRED MAINTENANCE 853 4 33 5 8 FUEL INLET BATTERY CONNECTION POSITIVE 3 8 16 THD 4 PLACES REMOTE START CONNECTION 41 1 1 5 8 3 8 16 THD 4 PLACES OIL FILTER ACCESS COOLING AIR IN AIR OUT COOLING AIR I...

Page 79: ...PLUG NGK BPR6HS NGK BPR6HS NGK BPR6HS SPARK PLUG GAP 0 030 inch 0 76mm 0 030 inch 0 76mm 0 030 inch 0 76mm Nominal Resistances of Generator Windings at 68 f Generator Specifications TYPE RV 45G LP RV...

Page 80: ...Section 11 ELECTRICAL DATA Page 78 Electrical Schematic and Wiring Diagram Drawing No 0G4221 B...

Page 81: ...Section 11 ELECTRICAL DATA Page 79 Electrical Schematic and Wiring Diagram Drawing No 0G4221 B...

Page 82: ...PO Box 297 Whitewater WI 53190 www guardiangenerators com P N OG7515 REV A PRINTED IN THE USA 03 08...

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