Manuals
/
Generac Power Systems
/
Lawn and Garden
/
Portable Generator
Generac Power Systems
manual Diagnostic Repair Manual, QUIETPACT 55/65/75
Models:
65
75
55
1
1
92
92
Download
92 pages
22.21 Kb
1
2
3
4
5
6
7
8
<
>
Troubleshooting
Specs
7.- Generator Operating Diagram
Replacement Parts
TEST 5- WIRE CONTINUITY
Diagnostic Repair Manual
Rotor Assembly
Circuit Condition- Fault Shutdown
1.– Governor Adjustment Points
4.– Battery Charge Circuit
Page 1
Image 1
Diagnostic
Repair Manual
RECREATIONAL VEHICLE GENERATOR
For more information
www.guardiangenerators.com
QUIETPACT
®
55/65/75
Model 4702, 4703, 4707, 4705, 4706, 4707
Page 2
Page 1
Image 1
Page 2
Contents
QUIETPACT 55/65/75
Diagnostic Repair Manual
RECREATIONAL VEHICLE GENERATOR
Model 4702, 4703, 4707, 4705, 4706,
REPLACEMENT PARTS
SAFETY
NOTICE TO USERS OF THIS MANUAL
Table of Contents
SECTION
Table of Contents
MAGNETISM
Section GENERATOR FUNDAMENTALS
ELECTROMAGNETIC FIELDS
ELECTROMAGNETIC INDUCTION
A MORE SOPHISTICATED AC GENERATOR
A SIMPLE AC GENERATOR
Figure 1-5.– Alternating Current Sine Wave
Figure 1-6.– A More Sophisticated Generator
Section GENERATOR FUNDAMENTALS
Figure 1-7.- Generator Operating Diagram
GENERATOR AC CONNECTION SYSTEM
FIELD BOOST
Section GENERATOR FUNDAMENTALS
Section GENERATOR FUNDAMENTALS
Figure 1-8.– Connection for 120 Volts Only
STATOR ASSEMBLY
ROTOR ASSEMBLY
Section MAJOR GENERATOR COMPONENTS
Figure 2-1.Exploded View of Generator
Figure 2-4.– Battery Charge Circuit
BATTERY CHARGE COMPONENTS
Figure 2-5.– Schematic: Excitation Circuit
BRUSH HOLDER
Figure 2-6.– Excitation Circuit Breaker
CRANKCASE BREATHER
Section MAJOR GENERATOR COMPONENTS
Figure 2-9.– Control Panel Components
CONTROL PANEL COMPONENT IDENTIFICATION
Section MAJOR GENERATOR COMPONENTS
Section INSULATION RESISTANCE TESTS
CLEANING THE GENERATOR
EFFECTS OF DIRT AND MOISTURE
INSULATION RESISTANCE TESTERS
Section INSULATION RESISTANCE TESTS
STATOR INSULATION RESISTANCE
THE MEGOHMMETER
TESTING ROTOR INSULATION
Figure 3-2.– Stator Leads
Figure 3-3.– Rotor Test Points
METERS
Section MEASURING ELECTRICITY
THE VOM
MEASURING AC VOLTAGE
MEASURING CURRENT
MEASURING AC FREQUENCY
MEASURING RESISTANCE
Figure 4-3.– A Line-Splitter
OHMS LAW
ELECTRICAL UNITS
Figure
AMPERES = VOLTSOHMS
INTRODUCTION
Section ENGINE DC CONTROL SYSTEM
OPERATIONAL ANALYSIS
CIRCUIT CONDITION- PRIMING
Section ENGINE DC CONTROL SYSTEM
Page
CIRCUIT CONDITION- CRANKING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION-RUNNING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- SHUTDOWN
Section ENGINE DC CONTROL SYSTEM
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- FAULT SHUTDOWN
ENGINE CONTROLLER CIRCUIT BOARD
BATTERY
Figure 5-3.– Engine Controller Circuit Board
Figure 5-2.- Receptacle J1
START-STOPSWITCH
FUEL PRIMER SWITCH
Figure 5-5.– Primer Switch
7.5 AMP FUSE
Section ENGINE DC CONTROL SYSTEM
Figure 5-6.– Start-StopSwitch
STARTER CONTACTOR RELAY
& STARTER MOTOR
INTRODUCTION
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Figure 7-1.– Governor Adjustment Points
Section DIAGNOSTIC TESTS
TEST 1- CHECK NO-LOADVOLTAGE AND FREQUENCY
TEST 2- CHECK ENGINE GOVERNOR
TEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW
TEST 3- TEST EXCITATION CIRCUIT BREAKER
Figure 7-2.– Excitation “DPE” Circuit Breaker
Figure 7-3.- Fixed Excitation Test
Section DIAGNOSTIC TESTS
TEST 5- WIRE CONTINUITY
TEST 7 - TEST STATOR DPE WINDING
TEST 6- CHECK FIELD BOOST
Figure 7-4.- The Field Boost Circuit
Figure 7-5.– Stator Excitation Winding
Section DIAGNOSTIC TESTS
TEST 8- CHECK SENSING LEADS / POWER WINDINGS
TEST 9- CHECK BRUSH LEADS
Figure 7-6.– Stator Power Winding Leads
TEST 10 - CHECK BRUSHES & SLIP RINGS
Figure 7-7.– Brush Leads
Figure 7-8.– Rotor Assembly
TEST 11- CHECK ROTOR ASSEMBLY
TEST 12 - CHECK MAIN CIRCUIT BREAKER
Figure 7-9.– Main Breaker Typical
TEST 16 - CHECK BATTERY CHARGE RECTIFIER
TEST 15 - CHECK BATTERY CHARGE OUTPUT
TEST 13- CHECK LOAD VOLTAGE & FREQUENCY
TEST 14- CHECK LOAD WATTS & AMPERAGE
WINDINGS / BATTERY CHARGE RESISTOR
TEST 17 - CHECK BATTERY CHARGE
Figure 7-10.- Battery Charge Rectifier
Section DIAGNOSTIC TESTS
Figure 7-11.– Primer Switch
TEST 19- TEST PRIMER SWITCH
Figure 7-12.– Harness End of Connector
TEST 18 - TRY CRANKING THE ENGINE
Figure 7-13.- The LPG Fuel Solenoid FS
TEST 20- CHECK FUEL PUMP
Figure 7-14.– Electric Fuel Pump
Section DIAGNOSTIC TESTS
TEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD
TEST 22- CHECK BATTERY & CABLES
TEST 21- CHECK 7.5 AMP FUSE
Figure 7-15.– Harness to Fuel Pump
Figure 7-17.- Start-StopSwitch
TEST 24 - CHECK START-STOPSWITCH
Figure 7-18.– Test 24, Step
Section DIAGNOSTIC TESTS
TEST 26- CHECK STARTER CONTACTOR RELAY
TEST 25 - CHECK POWER SUPPLY TO WIRE
Figure 7-19.– Starter Contactor Relay
Section DIAGNOSTIC TESTS
TEST 27 - CHECK STARTER MOTOR
TEST 26A - CHECK STARTER CONTACTOR
Figure 7-20.– The Starter Contactor SC
STEP 1 TEST POINT
Figure 7-22.- Check Pinion Gear Operation
Figure 7-21.- Starter Motor SM
Section DIAGNOSTIC TESTS
TEST 28- CHECK FUEL SUPPLY
Figure 7-26.– Testing Starter Motor Performance
Figure 7-24.– Tachometer
Section DIAGNOSTIC TESTS
Figure 7-27- Typical Propane Gas Fuel System
Figure 7-28– LP Gas Carburetion Diagram
Section DIAGNOSTIC TESTS
TEST 30 - CHECK WIRE
TEST 29 - CHECK WIRE 14 POWER SUPPLY
Figure 7-30.– The 4-tabConnector
Figure 7-29.– Fuel Regulator
TEST 31 - CHECK FUEL SOLENOID GASOLINE MODELS
Figure 7-31.– Remote Harness Connector
TEST 32 - CHECK IGNITION SPARK
Section DIAGNOSTIC TESTS
Figure 7-33.– Checking Engine Miss
Figure 7-32.– Testing Ignition System
Figure 7-34.– Cylinder Balance Test
Section DIAGNOSTIC TESTS
Figure 7-35– Setting Spark Plug Gap
TEST 34 - CHECK AND ADJUST IGNITION MAGNETOS
Figure 7-36.– Ignition Magneto Assembly
TEST 33 - CHECK SPARK PLUGS
Armature Air Gap
Figure 7-37.– Setting Ignition Magneto
Figure 7-38.– Engine Ground Harness
Figure 7-39.– Diode Failure Diagnosis
Figure 7-41– Adjusting Valve Clearance
TEST 35 - CHECK VALVE ADJUSTMENT
Figure 7-40.- Engine Ground Harness Test Points
Section DIAGNOSTIC TESTS
TEST 37 - CHECK CHOKE SOLENOID
TEST 36 - CHECK CARBURETION
Figure 7-42- Tightening the Jam Nut
Section DIAGNOSTIC TESTS
Figure 7-44.– Exploded View of Choke Assembly
Figure 7-43.- Connector
Figure 7-45.– Automatic Choke Assembly
Section DIAGNOSTIC TESTS
TEST 38 - CHECK ENGINE / CYLINDER LEAK
DOWN TEST / COMPRESSION TEST
Section DIAGNOSTIC TESTS
TEST 40 - TEST OIL TEMPERATURE SWITCH
TEST 39 - CHECK OIL PRESSURE SWITCH
Figure 7-46.– Oil Pressure Switch
Figure 7-47.– Oil Temperature Switch
TEST 41 - TEST CHOKE HEATER
Figure 7-48.– Testing Oil Temperature Switch
TEST 42 - CHECK LPG FUEL SOLENOID
Section DIAGNOSTIC TESTS
Section DIAGNOSTIC TESTS
Figure 7-49.– Fuel Solenoid
MAJOR DISASSEMBLY
Section ASSEMBLY
Section ASSEMBLY
Figure 8-1.– Drive Belt Tension
10.Remove blower housing
Section ASSEMBLY
Page
NOTES
Base & Pulley – Drawing No. 0E1323-A
Section Exploded Views / Part Numbers
ITEM
Section Exploded Views / Part Numbers
PART NO. QTY
DESCRIPTION
Enclosure – Drawing No. 0E1011-B
Section Exploded Views / Part Numbers
Exploded Views / Part Numbers
Section
ITEM
PART NO
Sheet Metal – Drawing No. 0E1012-E
Section Exploded Views / Part Numbers
ITEM
Section Exploded Views / Part Numbers
Control Panel - Drawing No. 0E1013-A
Section Exploded Views / Part Numbers
0C2375
Section Exploded Views / Part Numbers
760 V-TwinEngine – Drawing No. 0E1014-B
Section Exploded Views / Part Numbers
0C5730A
Section Exploded Views / Part Numbers
LP Regulator - Drawing No. 0E1530
Section Exploded Views / Part Numbers
Exploded Views / Part Numbers
Section
0D5694
Section SPECIFICATIONS & CHARTS
GENERATOR SPECIFICATIONS
SPECIFICATIONS & CHARTS
NOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68F
Section
LONG BLOCK TORQUE REQUIREMENTS
ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS
TRIM TORQUE REQUIREMENTS
RV TORQUE REQUIREMENTS
Page
NOTES
Section ELECTRICAL DATA
Page
Section ELECTRICAL DATA
P/N OE7225 REV O
PO BOX 297 WHITEWATER, WI
PRINTED IN THE USA/9.03
