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Generac Power Systems Guardian 5410 Repair Manual

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

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Troubleshooting

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   Summary of Contents for Generac Power Systems Guardian 5410

  • Page 1

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

  • Page 2

    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.

  • Page 3: Table Of Contents

    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 ...

  • Page 4

    Table of Contents 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 –...

  • Page 5: 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.

  • Page 6: A Simple Ac Generator

    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.

  • Page 7

    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.

  • Page 8: Field Boost

    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.

  • Page 9

    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”...

  • Page 10: Major Generator Components

    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.

  • Page 11: Brush Holder

    Stator Leads 2 & 6 = Stator Excitation Winding Leads 11S & 22S = Voltage Sensing Leads Leads 11 & 22, 33 & 44 = AC Power Windings Figure 2-2. – Stator Output Leads BRUSH HOLdER The brush holder is retained in the rear bearing car- rier by two M5 screws.

  • Page 12: Crankcase Breather

    Section 2 MAJOR 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).

  • Page 13: Control Panel Component Identification

    Section 2 MAJOR GENERATOR COMPONENTS CONTROL PANEL COMPONENT IdENTIFICATION STARTER CONTACTOR RELAY (SCR) TERMINAL BLOCK (TB) “4-TAB CONNECTOR” CONTROL BOARD (PCB) WITH J1 CONNECTOR GOVERNOR ACTUATOR J2 CONNECTOR VOLTAGE REGULATOR (VR) WITH RED LED START/STOP SWITCH (SW1) WITH RED LED CIRCUIT BREAKERS 7.5 AMP DC FUSE (F1) (CB1 &...

  • Page 14: Insulation Resistance Tests

    Section 3 INSULATION RESISTANCE TESTS EFFECTS OF dIRT ANd MOISTURE Moisture and dirt 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 winding insula- tion.

  • Page 15: Stator Insulation Resistance

    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 ATTEMPT TO WORK WITH SOLvENTS IN ANY ENCLOSED AREA.

  • Page 16: Testing Rotor Insulation

    Section 3 INSULATION RESISTANCE TESTS Stator Leads 2 & 6 = Stator Excitation Winding Leads 11S & 22S = Voltage Sensing Leads Leads 11 & 22, 33 & 44 = AC Power Windings Figure 3-2. – Stator Leads TESTINg ROTOR INSULATION To test the Rotor for insulation breakdown, proceed as follows: Disconnect wires from the Rotor brushes or...

  • Page 17: Measuring Electricity

    METERS Devices used to measure electrical properties 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. ❏...

  • Page 18: Measuring Current

    Section 4 MEASURING 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.

  • Page 19: Electrical Units

    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 second.

  • Page 20: Engine Dc Control System

    Section 5 ENGINE DC CONTROL SYSTEM INTROdUCTION The engine DC control system includes all com- ponents necessary for the operation of the engine. Operation includes rest, priming, cranking, starting, running and shutdown. The system is shown sche- matically. OPERATIONAL ANALYSIS GOVERNOR ACTUATOR REMOTE...

  • Page 21

    CIRCUIT CONDITION – CRANkING: When the START-STOP SWITCH (SW1) or REMOTE PANEL START SWITCH is momentarily held in the “START” position and then released, Wire 17 from the Printed Circuit Board (PCB ) is connected to frame Ground. PCB action will then deliver battery voltage to a STARTER CONTACTOR RELAY (SCR) via Wire 56, and to an auto- matic CHOkE SOLENOID (CS) via Wire 14.

  • Page 22

    Section 5 ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION – RUNNING: With the FUEL PUMP (FP) and FUEL SOLENOID (FS) operating and ignition occurring, the engine should start, and the START- STOP SWITCH (SW1) is released. This voltage is delivered to the PCB via Wire 18A to prevent STARTER MOTOR engagement above a certain rpm.

  • Page 23

    CIRCUIT CONDITION – SHUTDOWN: Setting the START-STOP SWITCH (SW1) or the REMOTE PANEL START-STOP SWITCH to its “STOP” position connects the Wire 18 circuit to frame ground. Printed Circuit Board action then closes the circuit to Wire 18A, grounding the ignition magneto. PCB action de-energizes DC output to j1 plug to the FUEL PUMP (FP), FUEL SOLENOID (FS) and CHOkE HEATER (CH) are de-energized by the loss of DC to Wire 14.

  • Page 24: Printed Circuit Board

    Section 5 ENGINE 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 and off at the proper times.

  • Page 25: 7.5 Amp Fuse

    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 colder the weather, the larger the required cable diameter.

  • Page 26: Starter Contactor Relay & Starter Motor

    Section 5 ENGINE DC CONTROL SYSTEM a. With Wire 17 grounded, a Crank Relay on the circuit board energizes and battery voltage is delivered to the Starter Contactor Relay via Wire 56. The Starter Contactor Relay energizes, its contacts close and the Starter Contactor is energized via wire 16.

  • Page 27: Troubleshooting Flowcharts

    The “Flow Charts” in this section may be used in conjunction with the “Diagnostic Tests” of Section 7. Numbered tests in the Flow Charts correspond to identically numbered tests of Section 7. VOLTAGE & FREQUENCY GOOD – FREQUENCY BOTH HIGH OR LOW GO TO PROBLEM 1 REGULATOR ADUST- Problem 1 –...

  • Page 28: Problem

    Section 6 TROUBLESHOOTING FLOWCHARTS Problem 2 – Generator Produces Zero Voltage or Residual Voltage (5-12VAC) TEST 11 – CHECK MAIN CIRCUIT GOOD BREAKER RESET TO “ON” OR REPLACE IF BAD TEST 4 – PERFORM FIXED EXCITATION TEST / ROTOR AMP DRAW TEST 5 –...

  • Page 29: Excessive Voltage/frequency Droop When Load Is Applied

    Problem 2 – Generator Produces Zero Voltage or ResidualVoltage (5-12VAC) TEST 4 – PERFORM FIXED EXCITATION TEST / ROTOR AMP DRAW TEST 10 – CHECK ROTOR ASSEMBLY REPAIR REPLACE TEST ROTOR INSULATION, PAGE 14 Problem 3 – Excessive Voltage/Frequency Droop When Load is Applied (Underspeed Warning –...

  • Page 30: Engine Overspeed Warning Code Flashing On Sw1 Led (4 Flashes)

    Section 6 TROUBLESHOOTING FLOWCHARTS Problem 4 – Engine Overspeed Warning Code Flashing on SW1 LEd (4 Flashes) TEST 2 – CHECk STEPPER MOTOR GOOD CONTROL REPLACE STEPPER MOTOR Proble 5 – Priming Function Does Not Work (Gasoline Models) TEST 14 – TRY CRANKING THE ENGINE WON’T CRANK...

  • Page 31: Engine Will Not Crank

    Problem 6 - Engine Will Not Crank TEST 16 – CHECk 7.5 GOOD AMP FUSE FUSE BAD REPLACE FUSE FUSE BLOWS TEST 18 – CHECk POWER SUPPLY GOOD TO PRINTED CIRCUIT BOARD CHECk WIRING AND WIRE CONNECTIONS. REPAIR, RECONNECT OR REPLACE BAD TEST 21 –...

  • Page 32: Engine Cranks But Will Not Start (gasoline Units)

    Section 6 TROUBLESHOOTING FLOWCHARTS Problem 7 – Engine Cranks But Will Not Start (Gasoline Units) (Overcrank Warning Code on SW1 LED – 3 Flashes) TEST 25 – O.K. CHECK FUEL SUPPLY LOW FUEL REPLENISH FUEL SUPPLY TEST 15 – CHECK FUEL PUMP OPERATION TEST 29 –...

  • Page 33: Engine Cranks But Will Not Start (lp Units)

    Problem 7 – Engine Cranks But Will Not Start (LP Units) (Overcrank Warning Code on SW1 LED – 3 Flashes) TEST 25 – O.K. CHECK FUEL SUPPLY LOW LP PRESSURE REPLENISH FUEL SUPPLY TEST 41 – CHECK LPG FUEL SOLENOID TEST 29 –...

  • Page 34: Engine Starts Hard And Runs Rough (gasoline Units)

    Section 6 TROUBLESHOOTING FLOWCHARTS Problem 8 – Engine Starts Hard and Runs Rough (Gasoline Units) TEST 25 – CHECK GOOD FUEL SUPPLY LOW FUEL REPLENISH FUEL SUPPLY TEST 33 – CHECK CARBURETION ENGINE RUNS O.K. NOW STOP TESTS REPAIR OR REPLACE GOOD TEST 32 –...

  • Page 35: Engine Starts Hard And Runs Rough (lp Units)

    Problem 8 – Engine Starts Hard and Runs Rough (LP Units) TEST 29 – TEST 25 – CHECK GOOD IGNITION FUEL SUPPLY LOW FUEL ENGINE MISS IS APPARENT REPLENISH TEST 31 – CHECK FUEL AND ADJUST IGNITION SUPPLY MAGNETOS TEST 32 – CHECK VALVE GOOD ADJUSTMENT...

  • Page 36: Or Low Oil Pressure Fault (5 Flashes)

    Section 6 TROUBLESHOOTING FLOWCHARTS Problem 9 – High Oil Temperature Fault (6 Flashes) or Low Oil Pressure Fault (5 Flashes) LOW OIL PRESSURE – 5 FLASHES ON SW1 LED REPLENISH FUEL TEST 36 – CHECK OIL PRESSURE SWITCH REPLACE SWITCH HIGH OIL TEMPERATURE –...

  • Page 37: Problem 10 - 7.5 Amp (f1) Fuse Blowing

    Problem 10 – 7.5A (F1) Fuse Blowing INSTALL NEW FUSE BLOWS UPON 7.5 AMP FUSE INSTALLATION REMOVE WIRE 15 FROM JI HARNESS CONNECTOR. DOES FUSE BLOW? (SEE NOTE A) CHECK WIRE 15 FOR SHORT TO GROUND FUSE IS GOOD BUT BLOWS WHEN START- STOP SWITCH IS PRESSED...

  • Page 38: Diagnostic Tests

    Section 7 DIAGNOSTIC TESTS INTROdUCTION The “Diagnostic Tests” in this chapter may be per- formed in conjunction with the “Flow Charts” 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 generator’s AC output voltage and frequency (Problems 1 through 3 in the “Flow Charts”).

  • Page 39: Fixed Excitation Test/rotor Amp Draw

    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 switches on the Printed Circuit Board are factory set in the “OFF”...

  • Page 40: Test

    Section 7 DIAGNOSTIC TESTS VOLTAGE RESULTS ABOVE WIRE 2 & 6 60 VAC ExCITATION WINDING VOLTAGE RESULTS ABOVE WIRE 11S & 22S 60 VAC POWER WINDING SENSE LEADS ROTOR AMP DRAW 1.1 A RV45 ± 20% (MODEL 5410/5411) ROTOR AMP DRAW .85 A RV55 ±...

  • Page 41: Check Field Boost

    1.11 Amp BLACK TEST LEAD 13 13 RED TEST LEAD FUSE HOLDER (F1) WIRES 4 REMOVED FROM VOLTAGE REGULATOR 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 between Wire 4 and 12 volt supply.

  • Page 42: Check Sensing Leads/power Windings

    Section 7 DIAGNOSTIC TESTS A. Schematic 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.

  • Page 43: Check Brush Leads

    AC POWER WINDING RESISTANCE RV45 (Model 5410/5411) ACROSS WIRES: OHMS Ω 11 & 22 0.396 Ω 11S & 22S 0.396 Ω 33 & 44 0.396 AC POWER WINDING RESISTANCE RV55 (Model 5412/5413) ACROSS WIRES: OHMS Ω − 0.32Ω 11 & 22 0.28 Ω...

  • Page 44: Check Brushes & Slip Rings

    Section 7 DIAGNOSTIC TESTS 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 develop on the slip rings.

  • Page 45: Check Main Circuit Breaker

    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 is in the “ON”...

  • Page 46: Try Cranking The Engine

    Section 7 DIAGNOSTIC TESTS TEST 14 – TRY CRANkINg THE ENgINE DISCUSSION: If the Start-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”.

  • Page 47: Check 7.5 Amp Fuse

    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 Fuse. RESULTS: If the Fuse element has melted open, replace the Fuse with an identical size fuse.

  • Page 48: Check Continuity Of Wire 17

    Section 7 DIAGNOSTIC TESTS 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.

  • Page 49: Check Power Supply To Wire 56

    0000 CONTINUITY 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 Switch (SW1) failed any part of Steps 2 or 3, replace the switch.

  • Page 50: Check Starter Contactor

    Section 7 DIAGNOSTIC TESTS “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 Starter Contactor Relay (SCR).

  • Page 51

    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 (SCR).

  • Page 52

    Section 7 DIAGNOSTIC TESTS 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 Figure 7-25.

  • Page 53: Check Fuel Supply

    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 have used a generator fuel pickup tube that is shorter than the vehicle engine’s pickup tube.

  • Page 54: Check Wire 14 Power Supply

    Section 7 DIAGNOSTIC TESTS 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 that is proportional to airflow through the generator.

  • Page 55: Test 27 - Check Wire 18

    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.

  • Page 56: Check Ignition Spark

    • Engine starts hard, runs rough. A commercially available spark tester may be used to test the engine ignition system. One can also be pur- chased from Generac Power Systems (P/N 0C5969). PROCEDURE: 1. Disconnect a high tension lead from a spark plug.

  • Page 57: Check Spark Plugs

    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 DISCUSSION: During Test 29, if spark jumped the tester gap, the...

  • Page 58

    Section 7 DIAGNOSTIC TESTS 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 ground.

  • Page 59: Check Valve Adjustment

    3. If “Infinity” was not measured in Step 15, repair or replace grounded Wire 18A between the j1 Connector and the insulated terminal stud or defective insulated terminal stud. 4. If sparking still does not occur after adjusting the armature air gap, testing the ground wires and performing the basic flywheel test, replace the ignition magneto(s).

  • Page 60: Check Carburetion

    Section 7 DIAGNOSTIC TESTS TEST 33 – CHECk CARBURETION DISCUSSION: If the engine cranks but will not start, one possible cause of the problem might be the carburetion system. PROCEDURE: Before making a carburetion check, be sure the fuel sup- ply tank has an ample supply of fresh, clean gasoline.

  • Page 61: Check Engine / Cylinder Leak Down Test / Compression Test

    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 PLUNGER CHOKE SOLENOID MOVES VERTICALLY Figure 7-42. – Choke Solenoid Adjustment 4.

  • Page 62: Check Oil Pressure Switch

    Section 7 DIAGNOSTIC TESTS 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 disassembling the engine.

  • Page 63: Test Wire 86 For Continuity

    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 terminals, with engine shut down.

  • Page 64: Test Wire 85 For Continuity

    Section 7 DIAGNOSTIC TESTS 3. Connect the test leads of a VOM across the switch terminals. The meter should read “Infinity”. 4. Heat the oil. When oil temperature reach- es approximately 270-284° F., the switch con- tacts should close and the meter should read “Continuity”.

  • Page 65: Check Lpg Fuel Solenoid

    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.

  • Page 66: Exploded Views / Part Numbers

    Section 9 Exploded views Base & Pulley – Drawing No. 0G7720-B Page 64...

  • Page 67

    ITEM QTY. DESCRIPTION TRAY, 530 RV NUT FLANGE 5/16-18 LOCk NUT HEx 5/16-18 STEEL WASHER LOCk M8-5/16 WASHER FLAT 5/16-M8 ZINC SCREW HHC 3/8-24 x 1-1/2 G8 BELT V-RIBBED 4L x 43.75" LG WASHER LOCk M10 WASHER FLAT 3/8-M10 ZINC ALTERNATOR PULLEY VIB MNT 1.5x1.38x5/16-18 DR 45 FAN 7"...

  • Page 68: Enclosure Drawing

    Section 9 Exploded views Enclosure – Drawing No. 0G3881-C Page 66...

  • Page 69

    ITEM QTY. DESCRIPTION ENCLOSURE DOOR SLIDE LATCH, FLUSH FOAM ENCLOSURE DOOR NUT FLANGE M6-1.0 NYLOk NUT FLANGE M6-1.0 NYLOk (LP) BRACkET, ENCLOSURE ELECTRIC HTR GROMMET, OIL FILTER U CHANNEL 1/8” TRAY, 530 RV GASkET AIR IN BOTTOM DUCT PLUG PLASTIC 1.093-1.125 GASkET AIR IN TOP DUCT DUCT AIR IN ROOF SCREW HHTT M6-1.0x12 ZINC...

  • Page 70: Control Panel Drawing

    Section 9 Exploded views Control Panel – Drawing No. 0G5489-D Page 68...

  • Page 71

    ITEM QTY. DESCRIPTION SCrEW HHC M6-1.0 X 25 G8.8 SCrEW PLaStItE HI-LOW #10X3/8 BUSHING SNaP SB-1093-937 WIrE HarNESS C/PNL FraME NUt HEX M6 X 1.0 G8 YEL CHr WaSHEr FLat 1/4-M6 ZINC WaSHEr LOCK SPECIaL 1/4" FUEL PUMP MOUNtING BraCKEt 28.75”...

  • Page 72: Engine Accessories Drawing

    Section 9 Exploded views Engine Accessories – Drawing No. 0G7718-B Page 70...

  • Page 73

    ITEM QTY. DESCRIPTION FraME ENGINE WraPPEr, StartEr SIDE SCrEW HHFC M8-1.25 X 14 SNaP BUSHING SCrEW CrIMPtItE 10-24 X 1/2 SHIELD WraPPEr, CYLINDEr #1 SCrEW HHFC M6-1.0 X 12 G8.8 ENGINE WraPPEr, BaCK BaCKPLatE aSSY, FLYWHEEL & rING GEar 29D aSSY, GrOUND WIrE CONNECtOr WaSHEr,BELV-20 X 2.2 NUt HEX M20-1.5 G8...

  • Page 74: Rv Engine Drawing

    Section 9 Exploded views 530 RV Engine – Drawing No. 0G7719-B 1,24,39,44,48 48,49 24,27,28,29,30,31,32,33,34,35,36,39,41 24,27,28,29,30,31,32,33,34,35,39,41,46 Page 72...

  • Page 75

    ITEM QTY. DESCRIPTION SEaL D 35 X 48.2 3/8” SQUarE HEaD PLUG SCrEW HHFC M8 – 1.25 X 45 GEar COVEr SLEEVE DOWEL PIN 11/32 DIaMEtEr PrESSUrE rELIEF BaLL OIL PrESSUrE SPrING GEarOtOr, OUtEr GEarOtOr, INNEr SCrEEN, OIL PICK-UP COVEr, GErOtOr SCrEW, HHFCS M6-1.0 x 12 BrEatHEr SEParatOr GEar, GEarOtOr...

  • Page 76: Rotor And Stator Drawing

    Section 9 Exploded views Rotor & Stator – Drawing No. 0G3953-b Page 74...

  • Page 77

    ITEM QTY. DESCRIPTION NUt tOP LOCK FL M8-1.25 WaSHEr, SPrNG CENtEr SPrING, GEN. MOUNt SUPPOrt, SLIDE SLIDE, NYLON SCrEW HHC M8-1.25 X 70 G8.8 WaSHEr FLat 5/16-M8 ZINC StUD, 530 rV StatOr tENSION SPrING WaSHEr, SPrING CENtr LOWEr BEarING CarrIEr rOtOr StatOr UPPEr BEarING CarrIEr...

  • Page 78: Specifications & Charts

    Section 10 SPECIFICATIONS & CHARTS Major Features and Dimensions – Drawing No. 0G5519-b Page 76...

  • Page 79: Generator Specifications

    TYPE MODEL WEIGHT TYPE OF ROTOR RATED WATTS RATED VOLTS PHASE RATED MAx. CONTINUOUS CURRENT AMPS (240V) RATED FREqUENCY OPERATING SPEED ENGINE MODEL TYPE OF ENGINE FUEL SYSTEM COOLING SYSTEM OIL SYSTEM Pressurized with Filter OIL PUMP AIR CLEANER STARTER IGNITION SYSTEM Solid State/Flywheel SPARk PLUG...

  • Page 80: Electrical Data

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

  • Page 81: Electrical Data

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

  • 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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