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Diagnostic
Diagnostic
Repair Manual
Repair Manual
RECREATIONAL VEHICLE GENERATOR
For more information
www.guardiangenerators.com
®
QUIETPACT 55/65/75
Model 4702, 4703, 4707, 4705, 4706, 4707
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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. D DA AN NG GE ER R!! U UN ND DE ER R T TH HIIS S H HE EA AD DIIN NG G W WIIL LL L B BE E F FO OU UN ND D S SP PE EC CIIA AL L IIN NS ST TR RU UC CT TIIO ON NS S W WH HIIC CH H,, IIF F N NO OT T C CO OM MP PL LIIE ED D W WIIT TH
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T Ta ab blle e o off C Co on ntte en ntts s S SA AF FE ET TY Y ........................................................ IIN NS SIID DE E F FR RO ON NT T C CO OV VE ER R S SE EC CT TIIO ON N 6 6:: T TR RO OU UB BL LE ES SH HO OO OT TIIN NG G F FL LO OW WC CH HA AR RT TS S ........................................ 2 27 7- -3 37 7 S SE EC CT TIIO ON N 1 1:: IF PROBLEM INVOLVES AC OUTPUT ...................... 27 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S ........
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T Ta ab blle e o off C Co on ntte en ntts s TEST 9 - TEST 35 - Check Brush Leads ...................................................... 43 Check Valve Adjustment .............................................. 61 TEST 10 - TEST 36 - Check Brushes & Slip Rings ........................................ 43 Check Carburetion ...................................................... 62 TEST 11 - TEST 37 - Check Rotor Assembly ................................................ 44 Check Choke Solenoid ..
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S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S NOTE: The “right hand rule” is based on the “cur- MAGNETISM rent flow” theory which assumes that current flows from positive to negative. This is opposite Magnetism can be used to produce electricity and the “electron” theory, which states that current electricity can be used to produce magnetism. flows from negative to positive. Much about magnetism cannot be explained by our present knowledge. However, t
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S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S 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 STA- TOR. The ROTOR is a permanent magnet which con- sists of a SOUTH magnetic pole and a NORTH mag- netic pole. As the MOTOR turns, its magnetic field cuts across the stationary STATOR. A voltage is induced Into the STATOR windings. Wh
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S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S Figure 1-7. – Generator Operating Diagram NOTE: AC output frequency at 3720 rpm will be (1) If the actual (sensing) voltage is greater about 62 Hertz. The “No-Load” is set slightly high than the pre-set reference voltage, the to prevent excessive rpm, frequency and voltage Regulator will decrease the regulated cur- droop under heavy electrical loading. rent flow to the Rotor. Generator operation may be des
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S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S You can use your generator set to supply electrical FIELD BOOST power for operating one of the following electrical loads: When the engine is cranked during startup, the engine's starter contactor is energized closed. Battery QUIETPACT 55G & LP: 120 and/or 240 volts, sin- current is then delivered to the starter motor and the gle phase, 60 Hz electrical loads. These loads can engine cranks. require up to
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S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S Figure 1-8. – Connection for 120 Volts Only RECONNECTION FOR DUAL VOLTAGE OUTPUT: When connected for dual voltage output, Stator out- Figure 1-9 - Connection for 120/240 Volts put leads 11P and 44 form two “hot” leads (T1- Red and T3- Black). The junction of leads 22P and 33 NOTE: If this generator has been reconnected for form the “Neutral” line (T2- White). dual voltage AC output (120/240 volts), the rep
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S Se ec cttiio on n 2 2 M MA AJ JO OR R G GE EN NE ER RA AT TO OR R C CO OM MP PO ON NE EN NT TS S Figure 2-1. Exploded View of Generator ROTOR ASSEMBLY STATOR ASSEMBLY The Rotor is sometimes called the “revolving field”, The Stator is “sandwiched” between the upper and since it provides the magnetic field that induces a lower bearing carriers and retained in that position by voltage into the stationary Stator windings. Slip rings four Stator studs. Windings Included in the Stator on the Ro
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S Se ec cttiio on n 2 2 M MA AJ JO OR R G GE EN NE ER RA AT TO OR R C CO OM MP PO ON NE EN NT TS S 3. Two excitation winding output leads (No. 2 and 6). These leads via the rectifier, a 7.5 amp fuse and Wire No. 13. A 1 ohm, 25 watt resistor is connected in series with the deliver unregulated excitation current to the voltage regulator. grounded side of the circuit. 4. Three (3) battery charge output leads (No. 55, 66 and 77). Figure 2-4. – Battery Charge Circuit EXCITATION CIRCUIT COMPONENTS
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S Se ec cttiio on n 2 2 M MA AJ JO OR R G GE EN NE ER RA AT TO OR R C CO OM MP PO ON NE EN NT TS S Rotor will be lost. The unit’s AC output voltage will ADJUSTMENT PROCEDURE: then drop to a value commensurate with the Rotor's With the frequency set at 62.5 Hertz and no load on residual magnetism (about 7-12 VAC). the generator, slowly turn the voltage adjust pot on the voltage regulator until 124 VAC is measured. If voltage is not adjustable, proceed to Section 6 - Troubleshooting; Problem
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S Se ec cttiio on n 2 2 M MA AJ JO OR R G GE EN NE ER RA AT TO OR R C CO OM MP PO ON NE EN NT TS S elbow. The breather chamber contains a removable 3. Remove oil vapor collector and retainer. oil vapor collector. Oil vapor is condensed on the col- 4. Check collector for deterioration and replace if necessary. lector material and drains back into the crankcase, which minimizes the amount of oil vapor entering the INSTALL BREATHER: breather. 1. Install oil vapor collector and retainer. CHECK
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S Se ec cttiio on n 3 3 IIN NS SU UL LA AT TIIO ON N R RE ES SIIS ST TA AN NC CE E T TE ES ST TS S D DA AN NG GE ER R!! IIN NS SU UL LA AT TIIO ON N R RE ES SIIS ST TA AN NC CE E EFFECTS OF DIRT AND MOISTURE T TE ES ST TE ER RS S S SU UC CH H A AS S H HII- -P PO OT T T TE ES ST TE ER RS S A AN ND D Moisture and dirt are detrimental to the continued M ME EG GO OH HM MM ME ET TE ER RS S A AR RE E A A S SO OU UR RC CE E O OF F H HIIG GH H good operation of any generator set. A AN ND
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S Se ec cttiio on n 3 3 IIN NS SU UL LA AT TIIO ON N R RE ES SIIS ST TA AN NC CE E T TE ES ST TS S C CA AU UT TIIO ON N!!:: S So om me e g ge en ne er ra atto or rs s m ma ay y u us se e e ep po ox xy y o or r STATOR SHORT-TO-GROUND TESTS: p po olly ye es stte er r b ba as se e w wiin nd diin ng g v va ar rn niis sh he es s.. U Us se e s so ollv ve en ntts s See Figure 3-2. To test the Stator for a short-to- tth ha att w wiillll n no ott a atttta ac ck k s su uc ch h m ma atte
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S Se ec cttiio on n 3 3 IIN NS SU UL LA AT TIIO ON N R RE ES SIIS ST TA AN NC CE E T TE ES ST TS S TEST BETWEEN PARALLEL WINDINGS: 3. Apply 1000 volts. DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. Connect the tester leads across Stator leads No. 11P and 33. Apply a voltage of 1500 volts. If an insulation If an insulation breakdown is indicated, clean and dry breakdown is indicated, clean and dry the Stator. the Rotor then repeat the test. Replace the Rotor if it Then, repeat the test between pa
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S Se ec cttiio on n 4 4 M ME EA AS SU UR RIIN NG G E EL LE EC CT TR RIIC CIIT TY Y METERS MEASURING AC VOLTAGE Devices used to measure electrical properties are An accurate AC voltmeter or a VOM may be used to called meters. Meters are available that allow one to read the generator's AC output voltage. The following measure (a) AC voltage, (b) DC voltage, (c) AC fre- apply: quency, and (d) resistance In ohms. The following 1. Always read the generator's AC output voltage only at the apply: unit
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S Se ec cttiio on n 4 4 M ME EA AS SU UR RIIN NG G E EL LE EC CT TR RIIC CIIT TY Y 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 frequen- cy 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. For models rated 60 Hertz, the governor is generally set to maintain a no-load freq
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S Se ec cttiio on n 4 4 M ME EA AS SU UR RIIN NG G E EL LE EC CT TR RIIC CIIT TY Y OHM: ELECTRICAL UNITS The OHM is the unit of RESISTANCE. In every circuit there is a natural resistance or opposition to the flow AMPERE: of electrons. When an EMF is applied to a complete The rate of electron flow in a circuit is represented by circuit, the electrons are forced to flow in a single the AMPERE. The ampere is the number of electrons direction rather than their free or orbiting pattern. The flowing
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S Se ec cttiio on n 5 5 E EN NG GIIN NE E D DC C C CO ON NT TR RO OL L S SY YS ST TE EM M INTRODUCTION The engine DC control system includes all com- ponents necessary for the operation of the engine. Operation includes rest, priming, crank- ing, starting, running and shutdown. The system is shown schematically. OPERATIONAL ANALYSIS CIRCUIT CONDITION- REST: Battery voltage is available to the engine controller cir- cuit board (PCB) from the unit BATTERY and via (a) the RED battery cable, Wire 1
