Related Manuals for Guardian Quietpact 55
Summary of Contents for Guardian Quietpact 55
- Page 1 Diagnostic Diagnostic Repair Manual Repair Manual RECREATIONAL VEHICLE GENERATOR www.guardiangenerators.com QUIETPACT ® Model 4702, 4703, 4707, 4705, 4706, 4707 For more information 55/65/75...
- 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. D D A A N N G G E E R R ! ! U U N N D D E E R R T T H H I I S S H H E E A A D D I I N N G G W W I I L L L L B B E E F F O O U U N N D D S S P P E E C C I I A A L L I I N N S S T T R R U U C C T T I I O O N N S S W W H H I I C C H H , , I I F F N N O O T T C C O O M M P P L L I I E E D D W W I I T T H H , , C C O O U U L L D D R R E E S S U U L L T T I I N N P P E E R R S S O O N N A A L L I I N N J J U U R R Y Y O O R R D D E E A A T T H H .
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Page 3: Table Of Contents
S S A A F F E E T T Y Y ............I I N N S S I I D D E E F F R R O O N N T T C C O O V V E E R R S S E E C C T T I I O O N N 1 1 : : G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S S . - Page 4 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s TEST 9 - Check Brush Leads ... 43 TEST 10 - Check Brushes &...
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Page 5: S S E E C C T T I I O O N N 1 1
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
S S e e c c t t i i o o n n 1 1 G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S S A SIMPLE AC GENERATOR Figure 1-4 shows a very simple AC Generator. - Page 7 NOTE: AC output frequency at 3720 rpm will be about 62 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.
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Page 8: Field Boost
M M o o d d e e l l C C i i r r c c u u i i t t B B r r e e a a k k e e r r 1 1 QuietPact 55 QuietPact 65... -
Page 9: G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S
Figure 1-8. – Connection for 120 Volts Only RECONNECTION FOR DUAL VOLTAGE OUTPUT: When connected for dual voltage output, Stator out- put leads 11P and 44 form two “hot” leads (T1- Red and T3- Black). The junction of leads 22P and 33 form the “Neutral”... -
Page 10: Rotor Assembly
S S e e c c t t i i o o n n 2 2 M M A A J J O O R R G G E E N N E E R R A A T T O O R R C C O O M M P P O O N N E E N N T T S S ROTOR ASSEMBLY The Rotor is sometimes called the “revolving field”, since it provides the magnetic field that induces a... -
Page 11: Brush Holder
3. Two excitation winding output leads (No. 2 and 6). These leads deliver unregulated excitation current to the voltage regulator. 4. Three (3) battery charge output leads (No. 55, 66 and 77). Figure 2-2. – Stator Output Leads BRUSH HOLDER The brush holder is retained in the rear bearing carri- er by two M5 screws. -
Page 12: Crankcase Breather
S S e e c c t t i i o o n n 2 2 M M A A J J O O R R G G E E N N E E R R A A T T O O R R C C O O M M P P O O N N E E N N T T S S Rotor will be lost. - Page 13 elbow. The breather chamber contains a removable oil vapor collector. Oil vapor is condensed on the col- lector material and drains back into the crankcase, which minimizes the amount of oil vapor entering the breather. CHECK BREATHER: 1. Disconnect breather tube and remove four screws and breather.
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Page 14: Effects Of Dirt And Moisture
S S e e c c t t i i o o n n 3 3 I I N N S S U U L L A A T T I I O O N N R R E E S S I I S S T T A A N N C C E E T T E E S S T T S S EFFECTS OF DIRT AND MOISTURE Moisture and dirt are detrimental to the continued good operation of any generator set. -
Page 15: Stator Insulation Resistance
C C A A U U T T I I O O N N ! ! : : S S o o m m e e g g e e n n e e r r a a t t o o r r s s m m a a y y u u s s e e e e p p o o x x y y o o r r p p o o l l y y e e s s t t e e r r b b a a s s e e w w i i n n d d i i n n g g v v a a r r n n i i s s h h e e s s . -
Page 16: Testing Rotor Insulation
S S e e c c t t i i o o n n 3 3 I I N N S S U U L L A A T T I I O O N N R R E E S S I I S S T T A A N N C C E E T T E E S S T T S S TEST BETWEEN PARALLEL WINDINGS: Connect the tester leads across Stator leads No. -
Page 17: Meters
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 fre- quency, and (d) resistance In ohms. The following apply: ❏ To measure AC voltage, use an AC voltmeter. ❏... -
Page 18: Measuring Ac Frequency
S S e e c c t t i i o o n n 4 4 M M E E A A S S U U R R I I N N G G E E L L E E C C T T R R I I C C I I T T Y Y MEASURING AC FREQUENCY The generator's AC output frequency is proportional to Rotor speed. -
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 electrons 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: Introduction
S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M Page 18 INTRODUCTION The engine DC control system includes all com-... - Page 21 S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M CIRCUIT CONDITION- PRIMING: When the FUEL PRIMER SWITCH (SW2) or the REMOTE PANEL FUEL PRIMER is closed by the oper-...
- Page 22 S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M Page 20 CIRCUIT CONDITION- CRANKING: When the START-STOP-SWITCH (SW1)or REMOTE...
- Page 23 S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M CIRCUIT CONDITION-RUNNING: With the FUEL PUMP (FP) and FUEL SOLENOID (FS) operating and ignition occurring, the engine should...
- Page 24 S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M Page 22 CIRCUIT CONDITION- SHUTDOWN: Setting the START-STOP SWITCH (SW1) or the...
- Page 25 S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M CIRCUIT CONDITION- FAULT SHUTDOWN: The engine mounts a HIGH OIL TEMPERA- TURE SWITCH (HTO) and a LOW OIL PRES-...
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Page 26: Engine Controller Circuit Board
S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M ENGINE CONTROLLER CIRCUIT BOARD GENERAL: The engine controller board is responsible for crank-... -
Page 27: 7.5 Amp Fuse
The following chart applies: C C A A B B L L E E L L E E N N G G T T H H ( ( I I N N F F E E E E T T ) ) R R E E C C O O M M M M E E N N D D E E D D C C A A B B L L E E S S I I Z Z E E 0-10 11-15... -
Page 28: Starter Contactor Relay & Starter Motor
S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M age is delivered to the Starter Contactor Relay via Wire 56.The Starter Contactor Relay energizes, its contacts close and the... -
Page 29: If Problem Involves Ac Output
The “Flow Charts” in this section may be used in con- junction with the “Diagnostic Tests” of Section 7. Numbered tests in the Flow Charts correspond to identically numbered tests of Section 7. T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S INTRODUCTION Problems 1 through 4 apply to the AC generator only. -
Page 30: Generator Produces Zero Voltage Or Residual Voltage (5-12 Vac)
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 28... -
Page 31: No Battery Charge Output
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 29... -
Page 32: Excessive Voltage/Frequency Droop When Load Is Applied
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 30... -
Page 33: Engine Will Not Crank
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 31... -
Page 34: Engine Cranks But Will Not Start (Gasoline Units)
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 32... -
Page 35: Engine Cranks But Will Not Start (Lp Units)
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 33... -
Page 36: Engine Starts Hard And Runs Rough (Gasoline Units)
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 34... - Page 37 S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 35...
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Page 38: Engine Starts Then Shuts Down
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 36... -
Page 39: Problem 10 - 7.5 Amp (F1) Fuse Blowing
S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 37... -
Page 40: Introduction
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S INTRODUCTION The “Diagnostic Tests”... -
Page 41: Test Excitation Circuit Breaker
GOVERNOR ADJUSTMENT 1. Loosen the GOVERNOR CLAMP BOLT. 2. Push Spring end of GOVERNOR LEVER clockwise to wide open throttle position of lever. a. Hold the GOVERNOR LEVER at wide open throttle and, with a pair of pliers, rotate the GOVERNOR SHAFT fully clockwise (CW). -
Page 42: Wire Continuity
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S VOLTAGE RESULTS ABOVE WIRE 2 &... -
Page 43: Check Field Boost
Excitation Circuit Breaker (CB3). Connect one test lead to one end of Wire 2A and the other test lead to the other end of the same wire. The meter should read continuity. RESULTS: If continuity was NOT measured across each wire, repair or replace the wires as needed. -
Page 44: Check Sensing Leads/Power Windings
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S PROCEDURE: 1. -
Page 45: Check Brush Leads
9. Connect the meter test leads across Stator lead 11P and frame ground. “Infinity” should be read. 10. Connect the meter test leads across Stator lead 33 and frame ground. The reading should be “Infinity”. 11. Connect the meter test leads across Stator leads Wire 11P and Wire 33. -
Page 46: Check Rotor Assembly
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 7. -
Page 47: Check Load Voltage & Frequency
RESULTS: 1. If breaker is “ON” and “Continuity” is measured, go to Test 3. 2. If breaker is “OFF”, reset to the “ON” position and check for AC output. 3. If breaker is “ON” and “Continuity” is not measured, replace the defective circuit breaker. -
Page 48: Check Battery Charge Windings/Battery Charge Resistor
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Short to Ground: 4. -
Page 49: Try Cranking The Engine
3. In Step 7, if Wire 0 reads “Continuity”, but resistor does not measure 1 ohm, replace the Battery Charge Resistor. 4. If all of the Steps in this test pass, perform “Insulation Resistance Test” on page 13. TEST 18 - TRY CRANKING THE ENGINE DISCUSSION: If the Fuel Primer Switch on the generator panel is actuated, but the Fuel Pump does not run (priming... -
Page 50: Check Fuel Pump
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Figure 7-13. -
Page 51: Check 7.5 Amp Fuse
3. If the pump fails Step 5 or Step 6, replace the Fuel Pump. Note: If desired, a pressure gauge can be attached to the pumps outlet side. Pump outlet pressure should be 2.0 to 3.5 psi. 4. If the pump operates normally, go to Test 31. Figure 7-15. -
Page 52: Check Start-Stop Switch
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S RESULTS: 1. -
Page 53: Check Power Supply To Wire 56
2. If engine cranks in Step 3 when Wire 17 is grounded, but will not crank when the Switch is set to “START”, replace the Start- Stop Switch. 3. If the Start-Stop Switch (SW1) failed any part of Steps 5 or 6, replace the switch. -
Page 54: Check Starter Contactor
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S RESULTS: 1. - Page 55 PROCEDURE: The battery should have been checked prior to this test and should be fully charged. Set a VOM to measure DC voltage (12 VDC). Connect the meter positive (+) test lead to the Starter Contactor stud which has the small jumper wire con- nected to the Starter.
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Page 56: Check Fuel Supply
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Figure 7-24. - Page 57 DISCUSSION (LPG MODELS): LP gas is stored in pressure tanks as a liquid. The gas systems used with these generators were designed only for vapor withdrawal type systems. Vapor withdrawal systems use the gas vapors that form above the liquid fuel in the tank. Do NOT attempt to use the generator with any liquid withdrawal type system.
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Page 58: Check Wire 14 Power Supply
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S water column as measured with a manometer. -
Page 59: (Gasoline Models)
• 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 (Part No. 0C5969). PROCEDURE: 1. Disconnect a high tension lead from a spark plug. - Page 60 S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 4.
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Page 61: Check Spark Plugs
TEST 33 - CHECK SPARK PLUGS DISCUSSION: During Test 32, if spark jumped the tester gap, the ignition system must be functioning properly. However, if the engine misses the spark plug itself may be fouled. PROCEDURE: Remove spark plugs. Clean with a commercial sol- vent. - Page 62 S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 3.
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Page 63: Check Valve Adjustment
measured. During cranking and running this read- ing should go to “Infinity”. Verify that the meter leads were properly connected as per Step 2 instructions. 2. If battery voltage was not measured in Step 3, reconnect Wire 15 and Wire 14 to their correct terminal locations. Figure 7-40. -
Page 64: Check Carburetion
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Figure 7-42 –... - Page 65 ment of the SOLENOID PLUNGER. Adjust SOLENOID PLUNGER movement until, with the carburetor CHOKE PLATE closed, the CHOKE SOLENOID is bottomed in its coil (plunger at full actuated position). With the CHOKE PLATE closed and the plunger bottomed in its coil, tighten the two screws. 4.
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Page 66: Check Engine / Cylinder Leak Down Test / Compression Test
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S TEST 38 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TEST GENERAL:... -
Page 67: Check Oil Pressure Switch
TEST 39 - CHECK OIL PRESSURE SWITCH DISCUSSION: Also see “Operational Analysis” on Pages 18-23. The Low Oil Pressure Switch is normally-closed, but is held open by engine oil pressure during cranking and startup. Should oil pressure drop below a safe level, the switch contacts will close to ground the Wire 85 circuit. -
Page 68: Test Choke Heater
S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Figure 7-48. - Page 69 SHORT TO GROUND: Set VOM to measure resistance. Disconnect Wire 14A from the LPG Fuel Solenoid. Connect one meter test lead to LPG Fuel Solenoid. terminal that Wire 14A was just removed from. Connect the other meter test lead to a clean frame ground. LPG Fuel Solenoid. coil resistance of approximately 30-32 ohms Should be measured.
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Page 70: Major Disassembly
S S e e c c t t i i o o n n 8 8 A A S S S S E E M M B B L L Y Y MAJOR DISASSEMBLY ENCLOSURE/PANEL REMOVAL: 1. Remove enclosure door. 2. -
Page 71: Belt Tensioning
BELT TENSIONING: Tighten all four stator stud nuts to compress the spring to one half inch (1/2”) between the washer and support slide. Tighten the two side bolts to compress the spring to 5/8 of an inch between the washer and bearing carrier (see Figure 8-1). -
Page 72: Flywheel/Magneto Removal
S S e e c c t t i i o o n n 8 8 A A S S S S E E M M B B L L Y Y 8. Remove two (2) bolts holding blower housing on each cylinder head (a 10mm socket is required). - Page 73 N N O O T T E E S S Page 71...
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Page 74: Base & Pulley Drawing
S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Base &... - Page 75 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 0E0196 FRAME, 760 ENGINE 022129...
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Page 76: Enclosure Drawing
S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Enclosure –... - Page 77 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . 0D8827 0A7215 029451 11.5 FT. 0D8825 0D3700 0D3700 090388 0D8979 0D8960 023484D 0E0594...
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Page 78: Sheet Metal Drawing
S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Sheet Metal –... - Page 79 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 045756 SCREW HHTT M6-1.0 X 10 YC 0D1131...
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Page 80: Control Panel Drawing
S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Control Panel –... - Page 81 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 0C2375 SCREW HHC M8-1.25 X 90 G8.8 022145...
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Page 82: Twin Engine Drawing
S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s 760 V-Twin Engine –... - Page 83 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 0C5730A ASSEMBLY, CRANKCASE RV 0C3008...
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Page 84: Lp Regulator Drawing
S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s LP Regulator –... - Page 85 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . 0D5694 075475 022264 043180 0C5765 0C6070* 0C4680* 0C4647 0C4643 0D3973 0C6606 026073 0D3308...
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Page 86: Major Features And Dimensions
S S e e c c t t i i o o n n 1 1 0 0 S S P P E E C C I I F F I I C C A A T T I I O O N N S S & & C C H H A A R R T T S S Major Features and Dimensions –... -
Page 87: Generator Specifications
TYPE QUIETPACT 55 MODEL 4702/4703 WEIGHT 326/329 pounds TYPE OF ROTOR Two-pole RATED WATTS 5500 RATED VOLTS PHASE 1-Phase RATED MAXIMUM 45.8 LOAD AMPERES RATED FREQUENCY 60 Hz OPERATING SPEED 2200 rpm ENGINE MODEL GTV-760 TYPE OF ENGINE Vertical Shaft... -
Page 88: Engine Speeds And Voltage Specifications
S S e e c c t t i i o o n n 1 1 0 0 S S P P E E C C I I F F I I C C A A T T I I O O N N S S & & C C H H A A R R T T S S ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS Listed below are normal running voltages, load voltages and frequency ranges. - Page 89 N N O O T T E E S S Page 87...
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Page 90: Electrical Schematic And Wiring Diagram
S S e e c c t t i i o o n n 1 1 1 1 E E L L E E C C T T R R I I C C A A L L D D A A T T A A Electrical Schematic and Wiring Diagram –... - Page 91 S S e e c c t t i i o o n n 1 1 1 1 E E L L E E C C T T R R I I C C A A L L D D A A T T A A Electrical Schematic and Wiring Diagram –...
- Page 92 PO BOX 297 WHITEWATER, WI 53190 www.guardiangenerators.com P/N OE7225 REV O PRINTED IN THE USA/9.03...