Guardian 4702 Repair Manual Download

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Diagnostic
Repair Manual

For more information

www.guardiangenerators.com

QUIETPACT

55/65/75

Model 4702, 4703, 4707, 4705, 4706, 4707

RECREATIONAL VEHICLE GENERATOR

Summary of Contents for 4702

Page 1: ...Diagnostic Repair Manual Diagnostic Repair Manual For more information www guardiangenerators com QUIETPACT 55 65 75 Model 4702 4703 4707 4705 4706 4707 RECREATIONAL VEHICLE GENERATOR ...

Page 2: ...s by which a service might be performed and of the possible hazards and or results of each method We have not under taken any such wide evaluation Therefore anyone who uses a procedure or tool not recommended by Generac must first satisfy himself that neither his nor the products safety will be endangered by the service procedure selected All information illustrations and specifications in this ma...

Page 3: ...G GI IN NE E D DC C C CO ON NT TR RO OL L S SY YS ST TE EM M 1 18 8 2 26 6 INTRODUCTION 18 OPERATIONAL ANALYSIS 18 23 ENGINE CONTROLLER CIRCUIT BOARD 24 BATTERY 24 7 5 AMP FUSE 25 FUEL PRIMER SWITCH 25 START STOP SWITCH 25 STARTER CONTACTOR RELAY STARTER MOTOR 26 S SE EC CT TI IO ON N 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S 2 27 7 3 37 7 IF PROBLEM INVOLVES...

Page 4: ... 36 Check Carburetion 62 TEST 37 Check Choke Solenoid 62 TEST 38 Check Engine Cylinder Leak Down Test Compression Test 64 TEST 39 Check Oil Pressure Switch 65 TEST 40 Test Oil Temperature Switch 65 TEST 41 Test Choke Heater 66 TEST 42 Check LPG Fuel Solenoid 66 S SE EC CT TI IO ON N 8 8 A AS SS SE EM MB BL LY Y 6 68 8 7 70 0 MAJOR DISASSEMBLY 68 Enclosure Panel Removal 68 Stator Removal 68 Rotor R...

Page 5: ...llowing rules apply The greater the current flow through the conductor the stronger the magnetic field around the conductor The increase in the number of lines of force is directly proportional to the increase in current flow and the field is distributed along the full length of the conductor The direction of the lines of force around a conduc tor can be determined by what is called the right hand...

Page 6: ...1 The 2 pole ROTOR must be turned at 3600 rpm to produce an AC frequency of 60 Hertz or at 3000 rpm to deliver an AC fre quency of 50 Hertz 2 The 4 pole ROTOR must operate at 1800 rpm to deliver a 60 Hertz AC frequency or at 1500 rpm to deliver a 50 Hertz AC frequency Figure 1 4 A Simple AC Generator Figure 1 5 Alternating Current Sine Wave A MORE SOPHISTICATED AC GENERATOR Figure 1 6 represents a...

Page 7: ...ge is delivered to the Voltage Regulator via sensing leads from the Stator AC power windings c The Regulator compares the actual sens ing voltage to its pre set reference voltage 1 If the actual sensing voltage is greater than the pre set reference voltage the Regulator will decrease the regulated cur rent flow to the Rotor 2 If the actual sensing voltage is less than the pre set reference voltage...

Page 8: ...an require up to 5500 watts 5 5 kW of total power but cannot exceed 45 8 AC amperes of current at 120 volts or exceed 22 9 AC amperes at 240 volts QUIETPACT 65G LP 120 and or 240 volts sin gle phase 60 Hz electrical loads These loads can require up to 6500 watts 6 5 kW of total power but cannot exceed 54 1 AC amperes of current at 120 volts or exceed 27 AC amperes at 240 volts QUIETPACT 75G LP 120...

Page 9: ...p main breakers the existing breakers may be re used when reconnecting for dual voltage output However on units with a 30 amp and a 20 amp main breaker you may wish to install a 2 pole breaker that is rated closer to the unit s rated capacity use two 25 amp main breakers Figure 1 9 Connection for 120 240 Volts NOTE If this generator has been reconnected for dual voltage AC output 120 240 volts the...

Page 10: ...ut or at 3000 rpm for a 50 Hertz output Slip rings may be cleaned If dull or tarnished clean them with fine sandpaper a 400 grit wet sandpaper is recommended DO NOT USE ANY METALLIC GRIT OR ABRASIVE TO CLEAN SLIP RINGS STATOR ASSEMBLY The Stator is sandwiched between the upper and lower bearing carriers and retained in that position by four Stator studs Windings Included in the Stator assembly are...

Page 11: ...r incorporates dual battery charge windings A battery charge rectifier BCR changes the AC out put of these windings to direct current DC Battery charge winding output is delivered to the unit battery 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 Figure 2 4 Battery Charge Circuit EXCITATION CIRCUIT COMPONENTS GE...

Page 12: ...62 5 Hertz and no load on 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 2 NOTE If for any reason sensing voltage to the regulator is lost the regulator will shut down and excitation output to the Rotor will be lost The AC output voltage will then drop to a value that is c...

Page 13: ...crews 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 Remove oil vapor collector and retainer 4 Check collector for deterioration and replace if necessary INSTALL BREATHER 1 Install oil vapor collector and retainer Note Push oil vapor collector and retainer in until it bottoms 2 Install breather with...

Page 14: ... H A AS S H HI I P PO OT T T TE ES ST TE ER RS S A AN ND D 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 HI IG GH H A AN ND D D DA AN NG GE ER RO OU US S E EL LE EC CT TR RI IC CA AL L V VO OL LT TA AG GE E F FO OL LL LO OW W T TH HE E T TE ES ST TE ER R M MA AN NU UF FA AC CT TU UR RE ER R S S I IN NS ST TR RU UC CT TI IO ON NS S C CA AR RE EF FU UL LL LY Y U US S...

Page 15: ...s manual Do NOT apply the voltage longer than one 1 second C CA AU UT TI IO ON N D DO O N NO OT T c co on nn ne ec ct t t th he e H Hi i P Po ot t T Te es st te er r o or r M Me eg go oh hm mm me et te er r t te es st t l le ea ad ds s t to o a an ny y l le ea ad ds s t th ha at t a ar re e r ro ou ut te ed d i in nt to o t th he e g ge en ne er ra at to or r c co on nt tr ro ol l p pa an ne el l ...

Page 16: ...tages must be disconnected before testing Isolate all Stator leads Figure 3 2 and connect all of the Stator leads together FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY Use a megger power setting of 1500 volts Connect one megger test lead to the junction of all Stator leads the other test lead to frame ground on the Stator can Read the number of megohms on the meter MINIMUM INSULATION GE...

Page 17: ...1 Always read the generator s AC output voltage only at the unit s rated operating speed and AC frequency 2 The generator s voltage regulator can be adjusted for correct output voltage only while the unit is operating at its correct rated speed and frequency 3 Only an AC voltmeter may be used to measure AC voltage DO NOT USE A DC VOLTMETER FOR THIS PURPOSE D DA AN NG GE ER R R RV V G GE EN NE ER R...

Page 18: ...thout disconnecting it Current flowing through a conductor may be mea sured safely and easily A line splitter can be used to measure current in a cord without separating the con ductors Figure 4 2 Clamp On Ammeter Figure 4 3 A Line Splitter NOTE If the physical size of the conductor or ammeter capacity does not permit all lines to be measured simultaneously measure current flow in each individual ...

Page 19: ... of EMF that will cause a current of 1 ampere to flow through 1 ohm of resistance Figure 4 4 Electrical Units OHM The OHM is the unit of RESISTANCE In every circuit there is a natural resistance or opposition to the flow of electrons When an EMF is applied to a complete circuit the electrons are forced to flow in a single direction rather than their free or orbiting pattern The resistance of a con...

Page 20: ... controller cir cuit 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 However circuit board action is holding the circuit open and no action can occur Battery output is available to the contacts of a STARTER CONTACTOR SC and STARTER CON TACTOR RELAY SCR but the contacts are open Battery voltage is also delivered to the ...

Page 21: ... 19 CIRCUIT CONDITION PRIMING When the FUEL PRIMER SWITCH SW2 or the REMOTE PANEL FUEL PRIMER is closed by the oper ator 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 ...

Page 22: ...es and its contacts close battery output is delivered to the STARTER MOTOR SM via Wire 16 The STARTER MOTOR energizes and the engine cranks When the STARTER CONTACTOR RELAY SCR closes Battery voltage is also delivered to the circuit board pin location J1 13 via Wire 16 This voltage is reduced and used for field boost and is outputted from pin location J1 9 While cranking the CHOKE SOLENOID CS is e...

Page 23: ... BATTERY CHARGE WINDING This voltage is delivered to the ENGINE CONTROLLER BOARD PCB via Wire 66 to prevent STARTER MOTOR engagement above a cer tain rpm Circuit board action terminates DC output to the STARTER CONTACTOR RELAY SCR which then de energizes to end cranking Circuit board action ter minates DC output to the CHOKE SOLENOID CS The choke will go to a position determined by the CHOKE HEATE...

Page 24: ...RT 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 Ignition and fuel flow terminate and the engine shuts down ...

Page 25: ...Circuit board action will then initiate a shutdown Should engine oil pressure drop below a safe pre set value the switch contacts will close On contact closure Wire 85 will be connected to frame ground and circuit board action will initiate an engine shutdown The circuit board has a time delay built into it for the Wire 85 fault shutdowns At STARTUP ONLY the circuit board will wait approximately 6...

Page 26: ...o Start Stop switch When grounded by set ting Switch to STOP engine shuts down 15 18 To Start Stop Switch on optional Remote Panel Figure 5 2 Receptacle J1 In addition to the 15 pin receptacle J1 the circuit board is equipped with two single pin terminals J2 and J3 These terminals may be identified as follows 1 Wire 14 connects to Terminal J2 During cranking and running the circuit board delivers ...

Page 27: ... IF FI IC C G GR RA AV VI IT TY Y P PE ER RC CE EN NT TA AG GE E O OF F C CH HA AR RG GE E 1 260 100 1 230 75 1 200 50 1 170 25 CHARGING A BATTERY Use an automotive type battery charger to recharge a battery Battery fluid is an extremely corrosive sulfu ric acid solution that can cause severe burns For that reason the following precautions must be observed The area in which the battery is being ch...

Page 28: ...und Figure 5 6 Start Stop Switch STARTER CONTACTOR RELAY STARTER MOTOR The positive battery cable attaches to the large lug on the STARTER CONTACTOR Wire 13 then attaches to one side of the STARTER CONTACTOR RELAY contact from this point Wire 13 attaches to the fuse F1 to supply battery voltage to the DC con trol system The opposite side of the starter contactor relay contact is connected to Wire ...

Page 29: ...rts 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 Problems 1 through 4 apply to the AC generator only Beginning with Problem 5 the engine DC control sys tem is dealt with Page 27 INTRODUCTION ...

Page 30: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 28 ...

Page 31: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 29 ...

Page 32: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 30 ...

Page 33: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 31 ...

Page 34: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 32 ...

Page 35: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 33 ...

Page 36: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 34 ...

Page 37: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 35 ...

Page 38: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 36 ...

Page 39: ...S Se ec ct ti io on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TI IN NG G F FL LO OW WC CH HA AR RT TS S Page 37 ...

Page 40: ...d T2 White 2 Disconnect or turn OFF all electrical loads Initial checks and adjustments are accomplished at no load 3 Start the engine let it stabilize and warm up 4 Read the AC voltage 5 Connect an AC frequency meter across AC output leads T1 Red and T2 White Repeat the above procedure RESULTS For units rated 60 Hertz no load voltage and frequen cy should be approximately 122 126 VAC and 61 63 He...

Page 41: ...rom the Stator excitation DPE winding The circuit breaker should re close or reset automatically after it cools down takes approximately two minutes When the breaker CB3 is open excitation current to the Regulator and to the Rotor will be lost The unit s AC output voltage will then drop to a value that is commensurate with the Rotor s residual magnetism about 5 12 volts AC This test will determine...

Page 42: ... CONTINUITY DISCUSSION The Voltage Regulator receives unregulated alternat ing current from the Stator Excitation Winding via Wires 2 6 and 2A It also receives voltage sensing from the Stator AC Power Windings via Wires 11 and 22 The regulator rectifies the AC from the Excitation Winding and based on the sensing signals regulates that DC current flow to the Rotor The rectified and regulated curren...

Page 43: ...med that the Field Boost is working Stop testing If volt age is not measured proceed to Step 4 4 Connect the positive test lead to Wire 16 at pin location J1 13 on the PCB see Figure 7 4 J1 J2 J3 connectors remain connected to PCB Connect the negative test lead to a clean frame ground 5 Set the Start Stop Switch to START During cranking only battery voltage should measure 11 12 VDC 6 Connect the p...

Page 44: ...to a pre set reference voltage The sensing voltage is delivered to the Voltage Regulator via Wires 11S and 22S If an open circuit exists in sensing leads 11S or 22S the normal reaction of an unprotected Regulator would be to increase the excitation current to the Rotor in an effort to increase the actual AC output voltage This would result in a full field condition and an extremely high AC output ...

Page 45: ...voltage the brush leads could be one possible cause of the problem This test will check Wires 4 and OK for an open circuit condition PROCEDURE 1 Set a VOM to its Rx1 scale and zero the meter 2 Disconnect Wire 4 from the Voltage Regulator and from the Rotor brush terminal 3 Connect the VOM test leads across each end of the wire The meter should read Continuity 4 Disconnect Wire OF from the Rotor Br...

Page 46: ...e Rotor bearing Connect the common test lead to the negative slip ring Read the resistance of the Rotor windings in OHMS ROTOR RESISTANCE M MO OD DE EL L O OH HM MS S QP55 4702 4703 14 88Ω QP65 4704 4705 10 81Ω QP75 4706 4707 14 50Ω 16 0Ω Resistance values In ohms at 20 C 68 F Actual readings may vary depending on ambient temperature A tolerance of plus or minus 5 is allowed 3 Set the VOM to its R...

Page 47: ...ttery Charge Winding a Battery Charge Rectifier and a Battery Charge Resistor During normal opera tion the battery charge output will vary between 1 to 2 amps depending on the load applied to the genera tor Battery Charge Winding Stator Lead Wire 66 is tapped at the Battery Charge Rectifier and connected to the Engine Control Circuit Board at Pin location J1 10 and is used as a signal for Starter ...

Page 48: ...ormal Battery Charge Winding resistance should be measured 4 Connect one test lead to Stator Lead Wire 55 Connect the other test lead to Stator Leads Wire 11 33 at the back of CB1 Infinity should be measured 5 Connect one test lead to Stator Lead Wire 55 Disconnect Stator Lead Wire 2 from the DPE circuit breaker CB3 and connect the other test lead to Wire 2 Infinity should be mea sured 6 Connect o...

Page 49: ...gative meter test lead to frame ground The meter should indicate battery voltage 3 Connect the positive meter test lead to the Wire 14 terminal of the Primer Switch leave Wire 14 connected to the switch Connect the negative meter test lead to a clean frame ground Set the Start Stop switch to START The engine should crank and battery voltage should be measured 4 Connect the positive meter test lead...

Page 50: ...el supply if questionable 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...

Page 51: ...re still suspected connect an alternate battery and cables to the generator and retest 2 Use a battery hydrometer to test the battery for a state of charge and b condition Follow the hydrometer manufactur er s instructions carefully RESULTS 1 Clean battery posts and cables as necessary Make sure bat tery cables are tight 2 Recharge the battery if necessary 3 Replace the battery if necessary 4 If b...

Page 52: ... switch is set to STOP PROCEDURE For Problem 6 Section 6 perform all steps For Problem 9 perform Step 1 and Step 5 ONLY 1 Set a VOM to its Rx1 scale and zero the meter 2 Inspect the ground Wire 0B between the Start Stop Switch and the grounding terminal Connect one meter test lead to Wire 0B on SW1 Connect the other test lead to a clean frame ground Continuity should be measured 3 Disconnect Wire ...

Page 53: ...ontroller Circuit Board Connect the other test lead to frame ground 6 Actuate the Start Stop Switch to the START position The meter should indicate battery voltage RESULTS 1 If battery voltage was measured in Step 6 but not in Step 4 repair or replace Wire 56 between the Engine Controller Circuit Board and Starter Contactor Relay 2 If battery voltage was not available in Step 6 replace the Engine ...

Page 54: ...ge should be indicated Reconnect Wire 16 to the Starter Contactor 3 Set the VOM to measure DC voltage Connect the positive meter test lead to the Starter Contactor stud that has the small jumper wire connected to the Starter 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 20 STEP 2 TEST POINT RESULTS 1 ...

Page 55: ...ver slowly by hand to be sure it rotates freely W WA AR RN NI IN NG G D DO O N NO OT T R RO OT TA AT TE E E EN NG GI IN NE E W WI IT TH H E EL LE EC CT TR RI IC C S ST TA AR RT TE ER R W WI IT TH H S SP PA AR RK K P PL LU UG GS S R RE EM MO OV VE ED D A AR RC CI IN NG G A AT T T TH HE E S SP PA AR RK K P PL LU UG G E EN ND DS S M MA AY Y I IG GN NI IT TE E T TH HE E G GA AS SO OL LI IN NE E V VA A...

Page 56: ...y 2 4 seconds 4 A starter motor in good condition will be within the following specifications M Mi in ni im mu um m r rp pm m 4 45 50 00 0 M Ma ax xi im mu um m A Am mp ps s 5 50 0 Note Nominal amp draw of starter in generator is 60 amps Figure 7 26 Testing Starter Motor Performance TEST 28 CHECK FUEL SUPPLY DISCUSSION GASOLINE MODELS If the engine cranks but won t start don t overlook the obvious...

Page 57: ... i in ns st ta al ll la at ti io on n o or r u us se e o of f u un na au ut th ho o r ri iz ze ed d c co om mp po on ne en nt ts s m ma ay y r re es su ul lt t i in n f fi ir re e o or r a an n e ex xp pl lo o s si io on n F Fo ol ll lo ow w a ap pp pr ro ov ve ed d m me et th ho od ds s t to o t te es st t t th he e s sy ys s t te em m f fo or r l le ea ak ks s N No o l le ea ak ka ag ge e i is s...

Page 58: ...er positive test lead to the 4 tab terminal connector the common test lead to frame ground 3 Crank the engine and the meter should read battery voltage If 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 Connect the negative test lead to a clean frame ground see Figure 5 3 Page 24 5 Crank the engine The m...

Page 59: ...ead 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 carbure tor Connect the other test lead to the carburetor body Continuity should be measured Short to Ground 7 Set the VOM to measure resistance Disconnect the bullet con nector going to the Fuel Solenoid Connect one m...

Page 60: ...ntial Tools Required 1 Two Ignition Testers Generac P N OC5969 Attach an ignition tester between the spark plug lead and each spark plug Figure 7 33 Start and run engine running at top no load speed and note spark at ignition testers If the spark is equal at both ignition testers the problem is not ignition related A spark miss will be readily apparent Now note RPM of engine Ground out one cylinde...

Page 61: ...e assembly must be replaced The air gap between the magneto and the flywheel magnet is between 0 012 to 0 015 The ignition magneto assembly Figure 7 36 consists of a ignition magneto b spark plug high tension lead and c spark plug boot Figure 7 36 Ignition Magneto Assembly In Test 32 a spark tester was used to check for engine ignition If sparking or weak spark occurred one possible cause might be...

Page 62: ...ntinuous tone indicates Continuity shorted diode An incomplete circuit open diode will be dis played as OL 13 Disconnect the engine ground harness from the ignition mag netos and stud connector see Figure 7 38 Figure 7 38 Engine Ground Harness Figure 7 39 Diode Failure Diagnosis 14 Connect the positive test lead to Connector A as shown in Figure 7 40 Connect the negative test lead to Connector B a...

Page 63: ...o load If the flywheel key becomes sheared or even partially sheared ignition timing can change Incorrect timing can result in hard starting or failure to start Remove and inspect flywheel key for damage TEST 35 CHECK VALVE ADJUSTMENT DISCUSSION The valve lash must be adjusted correctly in order to pro vide the proper air fuel mixture to the combustion chamber ADJUSTING VALVE CLEARANCE Adjust valv...

Page 64: ...r in bottom of carburetor bowl 3 The float is plastic and can be removed for access to the nee dle so it can be cleaned 4 With all of this removed carburetor cleaner can be used to clean the rest of the carburetor before reassembly 5 After cleaning carburetor with an approved carburetor cleaner blow dry with compressed air and reassemble Shelf life on gasoline is 30 days Proper procedures need to ...

Page 65: ... other test lead to frame ground Continuity should be measured 7 Set the VOM to measure resistance Disconnect Connector 1 Connect one meter test lead to Wire 90 Connector 1 Pin 2 going to the Choke Solenoid Connect the other meter test lead to Wire 0 Connector 1 Pin 1 Approximately 3 7 ohms should be measured Current draw of Choke Solenoid at nominal volt age is 3 4 amps Short to Ground 8 Set the ...

Page 66: ...sult in a failure of the engine to start or b rough operation 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 This will also result in high oil consumption NOTE It is extremely difficult to obtain an accu rate compression reading without special equip ment For that reason co...

Page 67: ...re Pressure should be above 10 psi RESULTS 1 In Step 3 if Continuity is not indicated replace the switch 2 If oil pressure checked good in Step 5 but Step 4 measured Infinity replace the low oil pressure switch 3 If oil pressure is below 10 psi determine cause of low oil pres sure Refer to Engine Service manual No 0E2081 for further engine service information Verify that the oil is the proper vis ...

Page 68: ...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 If battery voltage was not measured in Step 2 set the VOM to measure resistance Disconnect Connector 1 at the Choke Assembly Connect one meter test lead to Wire 14 Connector 1 Pin 3 going to the ...

Page 69: ...round 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 If the solenoid energized in Step 1 proceed to Test 32 2 If Continuity was not measured in Step 2 repair or replace Wire 0 between the LPG Fuel Solenoid FS and the Ground Terminal GT in the control pan...

Page 70: ... in duct base a 10mm socket is required STATOR REMOVAL 1 Perform enclosure panel removal steps 1 12 2 Remove six 6 air in duct base panel bolts from top of stator Remove air in duct base using a 10mm socket 3 Remove four 4 standoff bolts from top of stator a 13mm wrench is required 4 Disconnect Wire 4 and Wire 0 from the brush holder assembly 5 Remove two 2 brush holder assembly screws Remove the ...

Page 71: ...r 4 exhaust manifold bolts using a 6mm allen wrench 7 Remove last screw holding exhaust gasket to tray an 8mm socket is required 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 STARTER REMOVAL 1 Perform enclosure panel removal steps 1 7 2 Remove spark plug boot from spark plug left side...

Page 72: ...al steps 1 7 2 Remove spark plug boot from spark plug on left side Cylinder 1 3 Remove nine 9 bolts from cylinder 1 wrap Remove Cylinder 1 wrap using an 8mm socket 4 Remove five 5 bolts from crankcase wrap using an 8mm socket 5 Remove four 4 bolts from oil cooler oil duct Remove oil duct both a 10mm socket and an 8mm socket are required 6 Remove crankcase wrap 7 Remove five 5 bolts holding blower ...

Page 73: ...N NO OT TE ES S Page 71 ...

Page 74: ...S Se ec ct ti io on n 9 9 E Ex xp pl lo od de ed d V Vi ie ew ws s P Pa ar rt t N Nu um mb be er rs s Page 72 Base Pulley Drawing No 0E1323 A ...

Page 75: ...ONLY 30 075224A 1 PULLEY ENGINE 2100 RPM 5 5 KW ONLY 075224B 1 PULLEY ENGINE 2500 RPM 6 5 7 5 KW ONLY 31 0E0586 1 GASKET BOTTOM AIR OUT QPRV I IT TE EM M P PA AR RT T N NO O Q QT TY Y D DE ES SC CR RI IP PT TI IO ON N 32 0D7176 4 WASHER SELF LOCKING 1 DIA 12GA 33 0E1334 1 SCREEN BOTTOM AIR OUT 34 0D8824 1 TRAY V TWIN RV 35 081105 2 NUT FLG 5 16 18 LOCK 36 073118 1 SCREW HHC 3 8 24 X 2 1 4 G8 37 04...

Page 76: ...S Se ec ct ti io on n 9 9 E Ex xp pl lo od de ed d V Vi ie ew ws s P Pa ar rt t N Nu um mb be er rs s Page 74 Enclosure Drawing No 0E1011 B ...

Page 77: ... FOAM PANEL DOOR 1 2 THK QP RV 23 0E1486 1 HARNESS AC OUTPUT 5 5 6 5 7 5 KW ONLY 0E1774 1 HARNESS AC OUTPUT 5 0 7 0 KW 50 Hz ONLY 24 0D9099 1 CUST CONN 4KW RV REMOTE 25 074908 4 SCREW HHTT M5 0 8 X 10 BP 26 022473 1 WASHER FLAT 1 4 M6 ZINC 27 022097 1 WASHER LOCK M6 1 4 28 022507 1 SCREW HHC 1 4 20 X 1 2 G5 29 0742600149 1 WIRE ASM BATT NEG QP RV 30 0C7968 4 NUT HEX JAM 3 8 16 BRASS 31 022237 2 WA...

Page 78: ...S Se ec ct ti io on n 9 9 E Ex xp pl lo od de ed d V Vi ie ew ws s P Pa ar rt t N Nu um mb be er rs s Page 76 Sheet Metal Drawing No 0E1012 E ...

Page 79: ... 16 M8 ZINC 55 0D9403 1 LINKAGE CHOKE BELLCRANK CARB 56 0E1246 1 ASSEM CHOKE BRACKET GASOLINE ONLY 0D9400 1 BRACKET CHOKE LP ONLY I IT TE EM M P PA AR RT T N NO O Q QT TY Y D DE ES SC CR RI IP PT TI IO ON N 57 0A7095 2 RHMS 4 40 X 5 16SEMS 58 0D9404 1 SPRING CHOKE RETURN 59 0D9801A 1 WRAP VALLEY UPPER SPCC 60 0C3018A 1 WRAPPER UPR 1 W M8 WELD NUT 61 0D9680A 1 WRAP VALLEY GTV760 RV SPCC 62 0D1143A ...

Page 80: ...S Se ec ct ti io on n 9 9 E Ex xp pl lo od de ed d V Vi ie ew ws s P Pa ar rt t N Nu um mb be er rs s Page 78 Control Panel Drawing No 0E1013 A ...

Page 81: ...P 29 032300 1 HOLDER FUSE 30 092113 1 SWITCH SPDT ON MOM ON 31 087798 1 SWITCH 6A SPDT I IT TE EM M P PA AR RT T N NO O Q QT TY Y D DE ES SC CR RI IP PT TI IO ON N 32 055440 2 SCREW HHC M5 0 8 X 25 G8 8 33 0D9377 1 PANEL TOP CONTROL 34 054502 1 CIRCUIT BREAKER 3 X 1 35 031879 4 WASHER FLAT 4 ZINC 36 043182 4 WASHER LOCK M3 37 051714 4 NUT HEX M3 0 5 G8 YEL CHR 38 092234 1 ASSY POTTED RV CNTL 39 04...

Page 82: ...S Se ec ct ti io on n 9 9 E Ex xp pl lo od de ed d V Vi ie ew ws s P Pa ar rt t N Nu um mb be er rs s Page 80 760 V Twin Engine Drawing No 0E1014 B ...

Page 83: ...C2996 1 GEROTOR OUTER 29 0C3011 2 COVER OIL RELIEF 30 0C3009 2 SPRING OIL RELIEF 31 0C3010 2 BALL 1 2D OIL RELIEF 32 050873A 1 1 4 NPT PIPE PLUG I IT TE EM M P PA AR RT T N NO O Q QT TY Y D DE ES SC CR RI IP PT TI IO ON N 33 0C2991 2 E RING GOVERNOR ARM 34 0D1667A 1 ARM GOVERNOR 35 0C2988 1 THRUST WASHER GOVERNOR 36 0C2992 1 BUSHING GOVERNOR LOWER 37 0C5732 1 ASSEMBLY SUMP WITH SLEEVE 38 0C2993 1 ...

Page 84: ...S Se ec ct ti io on n 9 9 E Ex xp pl lo od de ed d V Vi ie ew ws s P Pa ar rt t N Nu um mb be er rs s Page 82 LP Regulator Drawing No 0E1530 ...

Page 85: ...0 0D3973 1 PLUG EXPANSION 16MM TWINREG 11 0C6606 1 BARBED STR 1 2 X 1 2NPT W VS 12 026073 2 PLUG STD PIPE 1 8 STEEL SQ HD 13 0D3308 2 WASHER FLAT 3 2MM ID X 10MM OD 14 070728 2 SCREW PFILHM M3 0 5 X 5 15 0C5764 1 SPRING REGULATOR 45N M 32MM 16 0C4643A 1 INLET TWIN REG 11 11 DIA 17 0C6066 1 SEAL INLET REGULATOR 18 0C5968 1 SUPPORT INLET SEAL 19 0C5759 1 PIN PIVOT ARM 20 0C5761 1 LEVER REGULATOR 21 ...

Page 86: ...S Se ec ct ti io on n 1 10 0 S SP PE EC CI IF FI IC CA AT TI IO ON NS S C CH HA AR RT TS S Page 84 Major Features and Dimensions Drawing No 0E1058 C ...

Page 87: ... Type Trochoid Type AIR CLEANER Paper element Paper element Paper element w foam pre cleaner w foam pre cleaner w foam pre cleaner STARTER 12 VDC electric 12 VDC electric 12 VDC electric IGNITION SYSTEM Solid State Solid State Solid State SPARK PLUG Champion RC12YC Champion RC12YC Champion RC12YC or equivalent or equivalent or equivalent SPARK PLUG GAP 0 030 inch 0 030 inch 0 030 inch 0 76mm 0 76m...

Page 88: ... SCREW INTO ALUMINUM 50 in lbs M6 1 TAPTITE SCREW INTO ALUMINUM 96 in lbs M6 1 TAPTITE SCREW INTO WELDNUT 96 in lbs M8 1 25 TAPTITE SCREW INTO ALUMINUM 18 ft lbs STARTER BRACKET TO BLOCK 18 ft lbs GOVERNOR LEVER PINCH BOLT 120 in lbs FLYWHEEL NUT 135 165 ft lbs SPARK PLUG 15 ft lbs RV TORQUE REQUIREMENTS EXHAUST OUTLET BOLTS 18 ft lbs STATOR BOLTS 7 2 8 8 ft lbs M6 1 TAPTITE SCREW INTO PIERCED HOL...

Page 89: ...N NO OT TE ES S Page 87 ...

Page 90: ...S Se ec ct ti io on n 1 11 1 E EL LE EC CT TR RI IC CA AL L D DA AT TA A Page 88 Electrical Schematic and Wiring Diagram Drawing No 0E1057 D ...

Page 91: ...S Se ec ct ti io on n 1 11 1 E EL LE EC CT TR RI IC CA AL L D DA AT TA A Page 89 Electrical Schematic and Wiring Diagram Drawing No 0E1057 D ...

Page 92: ...PO BOX 297 WHITEWATER WI 53190 www guardiangenerators com P N OE7225 REV O PRINTED IN THE USA 9 03 ...

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