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Generac Power Systems Guardian 5410 Repair Manual: Problem 10 - 7.5 Amp (f1) Fuse Blowing; Test

Diagnostic repair manual.
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INSTALL NEW
7.5 AMP FUSE
REMOVE WIRE 15
FROM JI HARNESS
CONNECTOR.
DOES FUSE BLOW?
(SEE NOTE A)
FUSE IS GOOD BUT
BLOWS WHEN START-
STOP SWITCH IS
PRESSED
DISCONNECT JI HARNESS
FROM ENGINE CONTROL-
LER CIRCUIT BOARD AND
CHECK WIRE 14 FOR
SHORT TO GROUND.
IS CONTINUITY PRESENT?
NO
CHECK CHOKE
SOLENOID AND
STARTER
CONTACTOR
RELAY
Problem 10 – 7.5A (F1) Fuse Blowing
FUSE BLOWS UPON
INSTALLATION
NO
YES
CHECK WIRE 15
FOR SHORT TO
GROUND
CHECK REMOTE
HARNESS WIRE 15
FOR SHORT TO
GROUND
PERFORM RESISTANCE TESTS ON FUEL PUMP, FUEL SOLENOID,
CHOKE HEATER AND REMOTE HARNESS WIRE 14 (SEE * BELOW).
YES
ALSO CHECK WIRE 14 TO EACH COMPONENT FOR SHORT TO GROUND.
* CHECK FOR CONTINUITY TO FRAME GROUND. CONNECT ONE TEST
LEAD TO THE POSITIVE WIRE FOR EACH COMPONENT. CONNECT THE
OTHER TEST LEAD TO FRAME GROUND. RESISTANCE SHOULD BE
MEASURED. IF CONTINUITY "0" IS 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".
STARTER CONTACTOR
RELAY PIN LOCATION
J1-1 TEST TO GROUND
CHOKE SOLENOID
PIN LOCATION J1-2
TEST TO GROUND
TROUBLESHOOTING FLOWCHARTS
CHECK THAT FUSE
HOLDER IS NOT
GROUNDED
FAIL
REPLACE
NOTE A:
PRINTED CIRCUIT
Disconnect harness from engine controller
BOARD
circuit board.
Gently bend red tabs outward and remove red
plastic pin guide.
Using a small flathead screwdriver, slide black
retainer tabs out away from Wire 15 pin
(orange).
Gently push pin out of harness and pull wire
out from back of plug, noting it's location for
reinstallation later.
Replace red pin guide and plug J1 harness
back into engine controller circuit board.
Replace fuse.
If fuse does not blow, replace engine controller
circuit board.
If fuse still blows, continue to next section of
Problem 10 flow chart.
REPLACE COMPONENT OR WIRE
CHECK WIRE 56
FAIL
FOR SHORT TO
GROUND
CHECK WIRE 90
FOR SHORT TO
FAIL
GROUND
Section 6
PASS
REPLACE HOLDER
REPAIR OR
REPLACE
COMPONENT
OR WIRE
Page 35

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