Diagnostic Repair Manual RECREATIONAL VEHICLE GENERATOR For more information www.guardiangenerators.
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.
Table of Contents SAFETY ............................ INSIDE FRONT COVER SECTION 1: GENERATOR FUNDAMENTALS ...................... 3-7 MAGNETISM ................................................................ ELECTROMAGNETIC FIELDS .................................... ELECTROMAGNETIC INDUCTION .............................. A SIMPLE AC GENERATOR ........................................ A MORE SOPHISTICATED AC GENERATOR ............ FIELD BOOST ..............................................................
Table of Contents TEST 9 Check Brush Leads ...................................................... TEST 10 Check Brushes & Slip Rings ........................................ TEST 11 Check Rotor Assembly ................................................ TEST 12 Check Main Circuit Breaker .......................................... TEST 13 Check Load Voltage & Frequency ................................ TEST 14 Check Load Watts & Amperage .................................. TEST 15 Check Battery Charge Output ...
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 patterns of behavior that are known. Application of these behavior patterns has led to the development of generators, motors and numerous other devices that utilize magnetism to produce and use electrical energy. See Figure 1-1.
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 MOTOR turns, its magnetic field cuts across the stationary STATOR. A voltage is induced Into the STATOR windings.
Section 1 GENERATOR FUNDAMENTALS Figure 1-7. – Generator Operating Diagram 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 follows: 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.
Section 1 GENERATOR FUNDAMENTALS FIELD BOOST When the engine is cranked during startup, the engine's starter contactor is energized closed. Battery current is then delivered to the starter motor and the engine cranks. Closure of the starter contactor contacts also delivers battery voltage to Pin 13 of an Engine Controller circuit board. The battery current flows through a 47 ohm, 2 watt resistor and a field boost diode, then to the Rotor via brushes and slip rings. This is called “Field Boost” current.
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 11P and 44 form two “hot” leads (T1- Red and T3- Black). The junction of leads 22P and 33 form the “Neutral” line (T2- White). For dual voltage output, the “Neutral” line remains grounded. NOTE: For units with two 30 amp or two 35 amp main breakers, the existing breakers may be reused when reconnecting for dual voltage output.
Section 2 MAJOR GENERATOR COMPONENTS Figure 2-1. Exploded View of Generator ROTOR ASSEMBLY STATOR 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 windings. The Rotor is driven by the engine at a constant speed through a pulley and belt arrangement.
Section 2 MAJOR GENERATOR COMPONENTS 3. Two excitation winding output leads (No. 2 and 6). These leads deliver unregulated excitation current to the voltage regulator. via the rectifier, a 7.5 amp fuse and Wire No. 13. A 1 ohm, 25 watt resistor is connected in series with the grounded side of the circuit. 4. Three (3) battery charge output leads (No. 55, 66 and 77). Figure 2-4. – Battery Charge Circuit Figure 2-2.
Section 2 MAJOR GENERATOR COMPONENTS Rotor will be lost. The unit’s AC output voltage will then drop to a value commensurate with the Rotor's residual magnetism (about 7-12 VAC). Figure 2-6. – Excitation Circuit Breaker VOLTAGE REGULATOR: Six (6) leads are connected to the voltage regulator as follows: • Two (2) SENSING leads deliver ACTUAL AC output voltage signals to the regulator. These are Wires No. 11S and 22S.
Section 2 MAJOR GENERATOR COMPONENTS elbow. The breather chamber contains a removable oil vapor collector. Oil vapor is condensed on the collector 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. Discard gasket. 2. Check to see that reed valve is not deformed (Figure 2-8). Note: Reed valve must form a complete seal around vent hole. 3.
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 Insulation. This will result in a reduced Insulation resistance and, eventually, the unit's AC output will be affected. Insulation used in the generator is moisture resistant.
Section 3 INSULATION RESISTANCE TESTS CAUTION!: Some generators may use epoxy or polyester base winding varnishes. Use solvents 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. PROVIDE ADEQUATE VENTILATION WHEN WORKING WITH SOLVENTS.
Section 3 INSULATION RESISTANCE TESTS TEST BETWEEN PARALLEL WINDINGS: Connect the tester leads across Stator leads No. 11P and 33. Apply a voltage of 1500 volts. If an insulation breakdown is indicated, clean and dry the Stator. Then, repeat the test between parallel windings. If the Stator fails the second test, replace it. 3. Apply 1000 volts. DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. If an insulation breakdown is indicated, clean and dry the Rotor then repeat the test.
Section 4 MEASURING ELECTRICITY METERS MEASURING AC VOLTAGE 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. ❏ To measure DC voltage, use a DC voltmeter. ❏ Use a frequency meter to measure AC frequency In “Hertz” or “cycles per second”.. ❏ Use an ohmmeter to read circuit resistance, in “ohms”.
Section 4 MEASURING ELECTRICITY MEASURING AC FREQUENCY The generator's AC output frequency is proportional to Rotor speed. Generators equipped with a 2-pole Rotor must operate at 3600 rpm to supply a frequency of 60 Hertz. Units with 4-pole Rotor must run at 1800 rpm to deliver 60 Hertz. Correct engine and Rotor speed is maintained by an engine speed governor.
Section 4 MEASURING ELECTRICITY 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 thousand million billion electrons per second. With alternating current (AC), the electrons flow first in one direction, then reverse and move in the opposite direction. They will repeat this cycle at regular intervals.
Section 5 ENGINE DC CONTROL SYSTEM INTRODUCTION The engine DC control system includes all components necessary for the operation of the engine. Operation includes rest, priming, cranking, starting, running and shutdown. The system is shown schematically. OPERATIONAL ANALYSIS CIRCUIT CONDITION- REST: Battery voltage is available to the engine controller circuit board (PCB) from the unit BATTERY and via (a) the RED battery cable, Wire 13, a 7.5 amp FUSE (F1), Wire 15 and circuit board Terminal J3.
Section 5 ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- PRIMING: When the FUEL PRIMER SWITCH (SW2) or the REMOTE PANEL FUEL PRIMER is closed by the operator, battery voltage is delivered across the closed switch contacts and to the FUEL PUMP (FP) via Wire 14A. The FUEL SOLENOID (FS) will be energized via Wire 14 during cranking and running.
Section 5 ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- CRANKING: When the START-STOP-SWITCH (SW1)or REMOTE PANEL START SWITCH is held at “START” position, Wire 17 from the Engine controller circuit board is connected to frame Ground. Circuit board action will then deliver battery voltage to a STARTER CONTACTOR RELAY (SCR) via wire 56, and to a automatic CHOKE SOLENOID (CS) via Wire 90.
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. A voltage is induced into the Stator's BATTERY CHARGE WINDING. This voltage is delivered to the ENGINE CONTROLLER BOARD (PCB) via Wire 66 to prevent STARTER MOTOR engagement above a certain rpm.
Section 5 ENGINE DC CONTROL SYSTEM 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. Circuit board action then closes the circuit to Wire 18A, grounding the ignition magneto. Circuit board action de-energizes DC output to Terminal J2. The FUEL PUMP (FP), FUEL SOLENOID (FS) and CHOKE HEATER (CH) are de-energized by the loss of DC to Wire 14.
Section 5 ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- FAULT SHUTDOWN: The engine mounts a HIGH OIL TEMPERATURE SWITCH (HTO) and a LOW OIL PRESSURE SWITCH (LOP). Should engine oil temperature exceed a preset value, the switch contacts will close. Wire 85 from the circuit board will connect to frame ground. Circuit board action will then initiate a shutdown. Should engine oil pressure drop below a safe pre-set value, the switch contacts will close.
Section 5 ENGINE DC CONTROL SYSTEM ENGINE CONTROLLER CIRCUIT BOARD GENERAL: The engine controller board is responsible for cranking, 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. It is powered by fused 12 VDC power from the unit battery. a. b. c. d. To operate the electric Fuel Pump (FP). To energize the Fuel Solenoid. To operate the Choke Heater.
Section 5 ENGINE DC CONTROL SYSTEM The following chart applies: CABLE LENGTH (IN FEET) 0-10 11-15 16-20 RECOMMENDED CABLE SIZE No. 2 No. 0 No. 000 EFFECTS OF TEMPERATURE: Battery efficiency is greatly reduced by a decreased electrolyte temperature. Such low temperatures have a decided numbing effect on the electrochemical action. Under high discharge rates (such as cranking), battery voltage will drop to much lower values in cold temperatures than in warmer temperatures.
Section 5 ENGINE DC CONTROL SYSTEM b. age 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. Its contacts close and the engine cranks. With Wire 17 grounded, a Run Relay on the circuit board energizes and battery voltage is delivered to the Wire 14 circuit. Battery voltage is delivered to the Fuel Pump, Fuel Solenoid, Choke Heater and the Remote Harness.
Section 6 TROUBLESHOOTING FLOWCHARTS INTRODUCTION 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. Problems 1 through 4 apply to the AC generator only. Beginning with Problem 5, the engine DC control system is dealt with.
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Section 7 DIAGNOSTIC TESTS INTRODUCTION 3. If AC output voltage and frequency are both “zero”, go to Test 12. The “Diagnostic Tests” in this chapter may be performed 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 17 are procedures Involving problems with the generator's AC output voltage and frequency (Problems 1 through 4 in the “Flow Charts”).
Section 7 DIAGNOSTIC TESTS 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). Use a minimum amount of force against the governor shaft. b. While holding the GOVERNOR SHAFT fully clockwise and the GOVERNOR LEVER at wide open throttle, tighten the GOVERNOR CLAMP BOLT to 70 inch-pounds (8 N-m). 3.
Section 7 DIAGNOSTIC TESTS TEST 4 RESULTS C D A B E F G VOLTAGE RESULTS WIRE 2 & 6 EXCITATION WINDING ABOVE 60 VAC ABOVE 60 VAC BELOW 60 VAC ZERO OR RESIDUAL VOLTAGE (5-12 VAC) BELOW 60 VAC BELOW 60 VAC ABOVE 60 VAC VOLTAGE RESULTS WIRE 11 & 22 POWER WINDING SENSE LEADS ABOVE 60 VAC BELOW 60 VAC ABOVE 60 VAC ZERO OR RESIDUAL VOLTAGE (5-12 VAC) BELOW 60 VAC BELOW 60 VAC ABOVE 60 VAC ROTOR AMP DRAW QP55 (MODEL 4702/4703) .85 A ± 20% .85 A ± 20% .85 A ± 20% ZERO CURRENT DRAW ≥1.
Section 7 DIAGNOSTIC TESTS 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. If continuity WAS measured, proceed to Test 6. Wire 16 between the Starter Contactor Relay and PCB. 2.
Section 7 DIAGNOSTIC TESTS PROCEDURE: 1. Disconnect Wire 2 from the Excitation Circuit Breaker. 2. Disconnect Wire 6 from the Voltage Regulator. 3. Set a VOM to its “Rx1” scale and zero the meter. 4. Connect the VOM test leads across the terminal ends of Wires 2 and 6. The VOM should indicate the resistance of the Stator Excitation (DPE) Windings. EXCITATION “DPE” WINDING RESISTANCE * (Measured Across Wires 2 & 6) MODEL OHMS QP55 (4702/4703) 1.41Ω − 1.63Ω QP65 (4704/4705) 1.59Ω − 1.84Ω QP75 (4706/4707) 1.
Section 7 DIAGNOSTIC TESTS 9. Connect the meter test leads across Stator lead 11P and frame ground. “Infinity” should be read. PROCEDURE: 1. Set a VOM to its “Rx1” scale and zero the meter. 10. Connect the meter test leads across Stator lead 33 and frame ground. The reading should be “Infinity”. 2. Disconnect Wire 4 from the Voltage Regulator and from the Rotor brush terminal. 11. Connect the meter test leads across Stator leads Wire 11P and Wire 33. The reading should be “Infinity”. 3.
Section 7 DIAGNOSTIC TESTS 7. Inspect the slip rings. a. If slip rings appear dull or tarnished they may be cleaned and polished with fine sandpaper. DO NOT USE ANY METALLIC GRIT TO CLEAN SLIP RINGS. (A 400 grit wet sandpaper is recommended). b. After cleaning slip rings, blow away any sandpaper residue. 2. If Rotor checks good, perform “Insulation Resistance Test,” on Page 14. RESULTS: 1. Replace bad brushes. Clean slip rings, if necessary. 2. If brushes and rings are good, go to Test 11.
Section 7 DIAGNOSTIC TESTS 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. TEST 13- CHECK LOAD VOLTAGE & FREQUENCY DISCUSSION: If engine speed appears to drop off excessively when electrical loads are applied to the generator, the load voltage and frequency should be checked.
Section 7 DIAGNOSTIC TESTS Short to Ground: 4. Set the VOM to measure resistance. Connect the positive (+) test lead to the case housing of the BCR. Connect the negative (-) test lead to an outer terminal. “Infinity” should be measured. Now connect the negative test lead to the BCR center terminal. “Infinity” should be measured. Next, connect the negative test lead to the remaining outer BCR terminal. Once again “Infinity” should be measured. other test lead to Stator Lead Wire 55.
Section 7 DIAGNOSTIC TESTS 3. In Step 7, if Wire 0 reads “Continuity”, but resistor does not measure 1 ohm, replace the Battery Charge Resistor. PROCEDURE: 1. Set a VOM to read battery voltage (12 VDC). 4. If all of the Steps in this test pass, perform “Insulation Resistance Test” on page 13. 2. Connect the positive (+) meter test lead to the Wire 15 terminal of the Primer Switch (leave Wire 15 connected to the switch). Connect the negative (-) meter test lead to frame ground.
Section 7 DIAGNOSTIC TESTS 3. Remove air filter access panel and air filter. Remove fuel hose from pump. Place a suitable container to catch fuel from fuel pump line. Activate fuel primer switch. Pump should operate and fuel should flow. If pump does not operate, proceed to Step 4. 4. In Test 19, Battery Voltage was checked at Connector 2. This step will test the ground wire. Disconnect Connector 2 at the Fuel Pump. Set the VOM to measure resistance.
Section 7 DIAGNOSTIC TESTS 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. PROCEDURE: 1. Inspect the battery cables and battery posts or terminals for corrosion or tightness. Measure the voltage at the terminal of the starter contactor and verify 11-12 volts DC is available to the generator during cranking.
Section 7 DIAGNOSTIC TESTS RESULTS: 1. If battery voltage is NOT indicated in Step 1, check continuity of: a. b. c. d. Wire 13 between Starter Contactor and Starter Contactor Relay. Wire 13 between Starter Contactor Relay and 7.5 Amp Fuse (F1). Wire 15 between the 7.5 Amp fuse (F1) and the Battery Charge Rectifier. Wire 15 between the Battery Charge Rectifier and the Engine Controller Board. Repair, reconnect or Replace bad wiring as necessary. 2.
Section 7 DIAGNOSTIC TESTS 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 StartStop Switch. 3. If battery voltage is available in Step 4 but engine does not crank, go to Test 26. 3. If the Start-Stop Switch (SW1) failed any part of Steps 5 or 6, replace the switch. TEST 26- CHECK STARTER CONTACTOR RELAY 4. If engine will not crank when Wire 17 is grounded, proceed as follows: a.
Section 7 DIAGNOSTIC TESTS RESULTS: 1. If “Continuity” is not measured in Step 1, repair or replace Wire 0 between the Starter Contactor Relay and the ground terminal. 2. If “Continuity” was not measured in Step 2 when the Start-Stop switch was activated to “START”, replace the Starter Contactor Relay. 3. If “Continuity” is measured in Step 2, go to Test 26A.
Section 7 DIAGNOSTIC TESTS 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 connected to the Starter. Connect the common (-) test lead to the Starter Motor frame. Set the Start-Stop Switch to its "START" position and observe the meter.
Section 7 DIAGNOSTIC TESTS 4. A starter motor in good condition will be within the following specifications: Minimum rpm 4500 Maximum Amps 50 Note: Nominal amp draw of starter in generator is 60 amps. Figure 7-24. – Tachometer TEST BRACKET: A starter motor test bracket may be made as shown in Figure 7-25. Figure 7-26. – Testing Starter Motor Performance Figure 7-25.
Section 7 DIAGNOSTIC TESTS 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. Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator.
Section 7 DIAGNOSTIC TESTS water column as measured with a manometer. The LP system must be able to maintain 11-14 inches water column under all load requirements. 1. Turn LP supply to generator off. 2. Remove the Gas Pressure Tap from the fuel regulator and install manometer to this port. battery voltage is not measured, proceed to Step 4. 4. Connect the positive (+) meter test lead to Terminal J2 on the Engine Controller Circuit Board.
Section 7 DIAGNOSTIC TESTS 5. Set the VOM to measure resistance. Disconnect Wire 0 from the Carburetor at the bullet connector. Connect one test lead to Wire 0 that goes to the control panel. Connect the other test lead to a clean frame ground. “Continuity” should be measured. 6. Connect one test lead to the Green Wire going to the carburetor. Connect the other test lead to the carburetor body. “Continuity” should be measured. Short to Ground: Figure 7-31. – Remote Harness Connector 3.
Section 7 DIAGNOSTIC TESTS 4. Crank the engine rapidly. Engine must be cranking at 350 rpm or more. If spark jumps the tester gap, you may assume the ignition system is working properly. Repeat on remaining cylinder spark plug. 5. To determine if an engine miss is ignition related, connect the spark tester in series with the high tension lead and the spark plug. Then, start the engine.
Section 7 DIAGNOSTIC TESTS 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. If the magneto is defective, the entire assembly must be replaced. The air gap between the magneto and the flywheel magnet is between 0.012” to 0.015”.
Section 7 DIAGNOSTIC TESTS 3. If Step 1 produced spark and Step 2 tested good, set the VOM to measure DC voltage. Connect one test lead to Wire 15 (J3 Terminal) on ECB. Connect the other test lead to frame ground. Battery voltage should be measured. Verify that Wire 15 is connected to J3 and that Wire 14 is connected to J2; if reversed the unit will produce no spark. 4. Rotate the flywheel until the magnet is under the module (armature) laminations (see Figure 7-37). 5. Place a 0.012-0.
Section 7 DIAGNOSTIC TESTS measured. During cranking and running this reading 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. way is provided for alignment only and theoretically carries no load. If the flywheel key becomes sheared or even partially sheared, ignition timing can change.
Section 7 DIAGNOSTIC TESTS ❏ Starting under load. Make sure all loads are disconnected or turned off before attempting to crank and start the engine. ❏ Check that the automatic choke is working properly. Figure 7-42 – Tightening the Jam Nut INSTALL ROCKER ARM COVER 1. Use a new rocker arm cover gasket. Install the rocker arm cover and retain with four screws. RESULTS: Adjust valves to specification and retest. If problem continues, go to Test 38.
Section 7 DIAGNOSTIC TESTS 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. Disconnect Connector 1: Set the VOM to measure DC voltage. Connect the positive (+) test lead to Wire 90 (Pin 2) of Connector 1 going to the control panel.
Section 7 DIAGNOSTIC TESTS TEST 38 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TEST GENERAL: Most engine problems may be classified as one or a combination of the following: ❏ Will not start. ❏ Starts hard. ❏ Lack of power. ❏ Runs rough. ❏ Vibration. ❏ Overheating. ❏ High oil consumption. One or more of the following will usually cause loss of compression: ❏ Blown or leaking cylinder head gasket. ❏ Improperly seated or sticking-valves. ❏ Worn Piston rings or cylinder.
Section 7 DIAGNOSTIC TESTS 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. Engine controller board action will then initiate an automatic shutdown.
Section 7 DIAGNOSTIC TESTS 2. If the Choke Plate did not open in Step 1, check the Choke Heater. Set the VOM to measure DC voltage. Disconnect Connector 1 at the Choke Assembly. Connect the positive (+) meter test lead to Wire 14 (Connector 1, Pin 3) going to the control panel. Connect the negative (-) meter test lead to a clean frame ground. Set the Start-Stop Switch to “START.” Battery voltage should be measured (see Figure 7-43 on Page 63). 3.
Section 7 DIAGNOSTIC TESTS 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. Current draw of the LPG Fuel Solenoid at nominal voltage Is approximately 380 milliamps or 0.380 amps. RESULTS: 1.
Section 8 ASSEMBLY MAJOR DISASSEMBLY ENCLOSURE/PANEL REMOVAL: 1. Remove enclosure door. 2. Remove the nine (9) enclosure roof bolts from the perimeter of the enclosure roof (a 10mm socket is required). 3. Remove six (6) enclosure side panel bolts from the outside perimeter Remove two (2) front & side enclosure panel bolts from the outside perimeter. Remove three (3) enclosure side panel bolts, located on the inside. Remove three (3) enclosure side panel nuts, two (2) on the top and one (1) on the side.
Section 8 ASSEMBLY 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). ENGINE REMOVAL: 1. Perform rotor removal steps 1-17. 8. Remove four (4) engine mounting bolts (using a 14mm socket). 9. Remove oil fill line mounting clamp. 10. Remove two (2) oil lines to oil filter adapter. 11. Remove engine.
Section 8 ASSEMBLY 8. Remove two (2) bolts holding blower housing on each cylinder head (a 10mm socket is required). 3. Remove nine (9) bolts from cylinder 1 wrap. Remove Cylinder 1 wrap (using an 8mm socket). 9. Loosen four (4) allen head bolts for intake manifold. Tilt manifold forward to gain clearance (using a 6mm allen wrench). 4. Remove five (5) bolts from crankcase wrap (using an 8mm socket). 10. Remove blower housing. 5. Remove four (4) bolts from oil cooler oil duct.
NOTES Page 71
Section 9 Exploded Views / Part Numbers Base & Pulley – Drawing No.
Section 9 Exploded Views / Part Numbers ITEM PART NO. QTY. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 0E0196 022129 022145 022259 0C7758 0C3168 0C2417 077603 0E0588 029451 0D8912 0E0571 0D8911 043107 0D9021 096289 0D8940 070006 070008 040976 056893 023897 0E1078 0C4138 043116 1 12 15 6 4 1 1 2 1 1.5 FT.
Section 9 Exploded Views / Part Numbers Enclosure – Drawing No.
Section 9 Exploded Views / Part Numbers ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 PART NO. QTY.
Section 9 Exploded Views / Part Numbers Sheet Metal – Drawing No.
Section 9 Exploded Views / Part Numbers ITEM PART NO. QTY.
Section 9 Exploded Views / Part Numbers Control Panel – Drawing No.
Section 9 Exploded Views / Part Numbers ITEM PART NO. QTY.
Section 9 Exploded Views / Part Numbers 760 V-Twin Engine – Drawing No.
Section 9 Exploded Views / Part Numbers ITEM PART NO. QTY. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15A 0C5730A 0C3008 090388 0C5372 0C3005 0C3003 0D8067A 0C2981C 071983 0C5848 021533 071980 0D4041 0C2983 0C2985A 1 1 6 1 1 3 1 1 4 2 2 2 1 1 2 15B 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0C2985B 0D4042 0A7811 0C2977 0C5943 0D4122A 0D3961 0C2978 093873 021374 0C2994 0C2997 0C2995 0C2996 0C3011 0C3009 0C3010 050873A 1 1 1 1 1 1 2 2 3 3 1 1 1 1 2 2 2 1 DESCRIPTION ASSEMBLY, CRANKCASE RV SEAL, 38 I.D.
Section 9 Exploded Views / Part Numbers LP Regulator – Drawing No.
Section 9 Exploded Views / Part Numbers ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 PART NO. 0D5694 075475 022264 043180 0C5765 0C6070* 0C4680* 0C4647 0C4643 0D3973 0C6606 026073 0D3308 070728 0C5764 0C4643A 0C6066 0C5968 0C5759 0C5761 0C6069 0C6731 0C6067 0C4706 0C6068 0C5762 045764 QTY. 1 4 4 4 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 8 DESCRIPTION CASTING, TWIN REGULATOR HOUSING SCREW PPHM M4-0.
Section 10 SPECIFICATIONS & CHARTS Major Features and Dimensions – Drawing No.
Section 10 SPECIFICATIONS & CHARTS GENERATOR SPECIFICATIONS TYPE QUIETPACT 55 QUIETPACT 65 QUIETPACT 75 MODEL 4702/4703 4704/4705 4706/4707 WEIGHT 326/329 pounds 328/331 pounds 330/333 pounds TYPE OF ROTOR Two-pole Two-pole Two-pole RATED WATTS 5500 6500 7500 RATED VOLTS 120 120 120 PHASE 1-Phase 1-Phase 1-Phase RATED MAXIMUM LOAD AMPERES 45.8 54.2 62.
Section 10 SPECIFICATIONS & CHARTS ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS Listed below are normal running voltages, load voltages and frequency ranges.
NOTES Page 87
Section 11 ELECTRICAL DATA Electrical Schematic and Wiring Diagram – Drawing No.
Section 11 ELECTRICAL DATA Electrical Schematic and Wiring Diagram – Drawing No.
PO BOX 297 WHITEWATER, WI 53190 www.guardiangenerators.com P/N OE7225 REV O PRINTED IN THE USA/9.
