Manuals
/
Generac Power Systems
/
Lawn and Garden
/
Portable Generator
Generac Power Systems
65, 55 PO BOX 297 WHITEWATER, WI, P/N OE7225 REV O, PRINTED IN THE USA/9.03
Models:
65
75
55
1
92
92
Download
92 pages
22.21 Kb
85
86
87
88
89
90
91
92
<
>
Troubleshooting
Specifications
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 92
Image 92
PO BOX 297 WHITEWATER, WI 53190
www.guardiangenerators.com
P/N OE7225 REV O
PRINTED IN THE USA/9.03
Page 91
Page 92
Image 92
Page 91
Contents
Diagnostic Repair Manual
QUIETPACT 55/65/75
RECREATIONAL VEHICLE GENERATOR
Model 4702, 4703, 4707, 4705, 4706,
NOTICE TO USERS OF THIS MANUAL
SAFETY
REPLACEMENT PARTS
Table of Contents
Table of Contents
SECTION
Section GENERATOR FUNDAMENTALS
MAGNETISM
ELECTROMAGNETIC FIELDS
ELECTROMAGNETIC INDUCTION
A SIMPLE AC GENERATOR
A MORE SOPHISTICATED AC GENERATOR
Figure 1-5.– Alternating Current Sine Wave
Figure 1-6.– A More Sophisticated Generator
Figure 1-7.- Generator Operating Diagram
Section GENERATOR FUNDAMENTALS
Section GENERATOR FUNDAMENTALS
FIELD BOOST
GENERATOR AC CONNECTION SYSTEM
Figure 1-8.– Connection for 120 Volts Only
Section GENERATOR FUNDAMENTALS
ROTOR ASSEMBLY
STATOR ASSEMBLY
Section MAJOR GENERATOR COMPONENTS
Figure 2-1.Exploded View of Generator
BATTERY CHARGE COMPONENTS
Figure 2-4.– Battery Charge Circuit
Figure 2-5.– Schematic: Excitation Circuit
BRUSH HOLDER
Section MAJOR GENERATOR COMPONENTS
CRANKCASE BREATHER
Figure 2-6.– Excitation Circuit Breaker
Section MAJOR GENERATOR COMPONENTS
CONTROL PANEL COMPONENT IDENTIFICATION
Figure 2-9.– Control Panel Components
CLEANING THE GENERATOR
Section INSULATION RESISTANCE TESTS
EFFECTS OF DIRT AND MOISTURE
INSULATION RESISTANCE TESTERS
STATOR INSULATION RESISTANCE
Section INSULATION RESISTANCE TESTS
TESTING ROTOR INSULATION
THE MEGOHMMETER
Figure 3-2.– Stator Leads
Figure 3-3.– Rotor Test Points
Section MEASURING ELECTRICITY
METERS
THE VOM
MEASURING AC VOLTAGE
MEASURING AC FREQUENCY
MEASURING CURRENT
MEASURING RESISTANCE
Figure 4-3.– A Line-Splitter
ELECTRICAL UNITS
OHMS LAW
Figure
AMPERES = VOLTSOHMS
OPERATIONAL ANALYSIS
Section ENGINE DC CONTROL SYSTEM
INTRODUCTION
Page
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- PRIMING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- CRANKING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION-RUNNING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- SHUTDOWN
CIRCUIT CONDITION- FAULT SHUTDOWN
Section ENGINE DC CONTROL SYSTEM
BATTERY
ENGINE CONTROLLER CIRCUIT BOARD
Figure 5-3.– Engine Controller Circuit Board
Figure 5-2.- Receptacle J1
FUEL PRIMER SWITCH
START-STOPSWITCH
Figure 5-5.– Primer Switch
7.5 AMP FUSE
Figure 5-6.– Start-StopSwitch
Section ENGINE DC CONTROL SYSTEM
STARTER CONTACTOR RELAY
& STARTER MOTOR
Section TROUBLESHOOTING FLOWCHARTS
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 DIAGNOSTIC TESTS
Figure 7-1.– Governor Adjustment Points
TEST 1- CHECK NO-LOADVOLTAGE AND FREQUENCY
TEST 2- CHECK ENGINE GOVERNOR
TEST 3- TEST EXCITATION CIRCUIT BREAKER
TEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW
Figure 7-2.– Excitation “DPE” Circuit Breaker
Figure 7-3.- Fixed Excitation Test
TEST 5- WIRE CONTINUITY
Section DIAGNOSTIC TESTS
TEST 6- CHECK FIELD BOOST
TEST 7 - TEST STATOR DPE WINDING
Figure 7-4.- The Field Boost Circuit
Figure 7-5.– Stator Excitation Winding
TEST 8- CHECK SENSING LEADS / POWER WINDINGS
Section DIAGNOSTIC TESTS
Figure 7-6.– Stator Power Winding Leads
TEST 9- CHECK BRUSH LEADS
TEST 10 - CHECK BRUSHES & SLIP RINGS
Figure 7-7.– Brush Leads
TEST 11- CHECK ROTOR ASSEMBLY
Figure 7-8.– Rotor Assembly
TEST 12 - CHECK MAIN CIRCUIT BREAKER
Figure 7-9.– Main Breaker Typical
TEST 15 - CHECK BATTERY CHARGE OUTPUT
TEST 16 - CHECK BATTERY CHARGE RECTIFIER
TEST 13- CHECK LOAD VOLTAGE & FREQUENCY
TEST 14- CHECK LOAD WATTS & AMPERAGE
TEST 17 - CHECK BATTERY CHARGE
WINDINGS / BATTERY CHARGE RESISTOR
Figure 7-10.- Battery Charge Rectifier
Section DIAGNOSTIC TESTS
TEST 19- TEST PRIMER SWITCH
Figure 7-11.– Primer Switch
Figure 7-12.– Harness End of Connector
TEST 18 - TRY CRANKING THE ENGINE
TEST 20- CHECK FUEL PUMP
Figure 7-13.- The LPG Fuel Solenoid FS
Figure 7-14.– Electric Fuel Pump
Section DIAGNOSTIC TESTS
TEST 22- CHECK BATTERY & CABLES
TEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD
TEST 21- CHECK 7.5 AMP FUSE
Figure 7-15.– Harness to Fuel Pump
TEST 24 - CHECK START-STOPSWITCH
Figure 7-17.- Start-StopSwitch
Figure 7-18.– Test 24, Step
Section DIAGNOSTIC TESTS
TEST 25 - CHECK POWER SUPPLY TO WIRE
TEST 26- CHECK STARTER CONTACTOR RELAY
Figure 7-19.– Starter Contactor Relay
Section DIAGNOSTIC TESTS
TEST 26A - CHECK STARTER CONTACTOR
TEST 27 - CHECK STARTER MOTOR
Figure 7-20.– The Starter Contactor SC
STEP 1 TEST POINT
Section DIAGNOSTIC TESTS
Figure 7-21.- Starter Motor SM
Figure 7-22.- Check Pinion Gear Operation
Figure 7-26.– Testing Starter Motor Performance
TEST 28- CHECK FUEL SUPPLY
Figure 7-24.– Tachometer
Section DIAGNOSTIC TESTS
Section DIAGNOSTIC TESTS
Figure 7-28– LP Gas Carburetion Diagram
Figure 7-27- Typical Propane Gas Fuel System
TEST 29 - CHECK WIRE 14 POWER SUPPLY
TEST 30 - CHECK WIRE
Figure 7-30.– The 4-tabConnector
Figure 7-29.– Fuel Regulator
Figure 7-31.– Remote Harness Connector
TEST 31 - CHECK FUEL SOLENOID GASOLINE MODELS
TEST 32 - CHECK IGNITION SPARK
Section DIAGNOSTIC TESTS
Figure 7-32.– Testing Ignition System
Figure 7-33.– Checking Engine Miss
Figure 7-34.– Cylinder Balance Test
Section DIAGNOSTIC TESTS
TEST 34 - CHECK AND ADJUST IGNITION MAGNETOS
Figure 7-35– Setting Spark Plug Gap
Figure 7-36.– Ignition Magneto Assembly
TEST 33 - CHECK SPARK PLUGS
Figure 7-37.– Setting Ignition Magneto
Armature Air Gap
Figure 7-38.– Engine Ground Harness
Figure 7-39.– Diode Failure Diagnosis
TEST 35 - CHECK VALVE ADJUSTMENT
Figure 7-41– Adjusting Valve Clearance
Figure 7-40.- Engine Ground Harness Test Points
Section DIAGNOSTIC TESTS
TEST 36 - CHECK CARBURETION
TEST 37 - CHECK CHOKE SOLENOID
Figure 7-42- Tightening the Jam Nut
Section DIAGNOSTIC TESTS
Figure 7-43.- Connector
Figure 7-44.– Exploded View of Choke Assembly
Figure 7-45.– Automatic Choke Assembly
Section DIAGNOSTIC TESTS
Section DIAGNOSTIC TESTS
DOWN TEST / COMPRESSION TEST
TEST 38 - CHECK ENGINE / CYLINDER LEAK
TEST 39 - CHECK OIL PRESSURE SWITCH
TEST 40 - TEST OIL TEMPERATURE SWITCH
Figure 7-46.– Oil Pressure Switch
Figure 7-47.– Oil Temperature Switch
Figure 7-48.– Testing Oil Temperature Switch
TEST 41 - TEST CHOKE HEATER
TEST 42 - CHECK LPG FUEL SOLENOID
Section DIAGNOSTIC TESTS
Figure 7-49.– Fuel Solenoid
Section DIAGNOSTIC TESTS
Section ASSEMBLY
MAJOR DISASSEMBLY
Figure 8-1.– Drive Belt Tension
Section ASSEMBLY
Section ASSEMBLY
10.Remove blower housing
NOTES
Page
Section Exploded Views / Part Numbers
Base & Pulley – Drawing No. 0E1323-A
Section Exploded Views / Part Numbers
ITEM
PART NO. QTY
DESCRIPTION
Section Exploded Views / Part Numbers
Enclosure – Drawing No. 0E1011-B
Section
Exploded Views / Part Numbers
ITEM
PART NO
Section Exploded Views / Part Numbers
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
0D5694
Section
Exploded Views / Part Numbers
Section SPECIFICATIONS & CHARTS
SPECIFICATIONS & CHARTS
GENERATOR SPECIFICATIONS
NOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68F
Section
ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS
LONG BLOCK TORQUE REQUIREMENTS
TRIM TORQUE REQUIREMENTS
RV TORQUE REQUIREMENTS
NOTES
Page
Section ELECTRICAL DATA
Section ELECTRICAL DATA
Page
PRINTED IN THE USA/9.03
PO BOX 297 WHITEWATER, WI
P/N OE7225 REV O
