Generac Power Systems 75 manual

Diagnostic Repair Manual Diagnostic Repair Manual For more information www .guardiangenerators.com QUIETP ACT ® 55/65/75 Model 4702, 4703, 4707, 4705, 4706, 4707 RECREA TIONAL VEHICLE GENERA TOR[...]

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 D A A N N G G E E R R ! ! U U N N D D E E R R T T H H I I S S H H E[...]

T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Page 1 S S A A F F E E T T Y Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I N N S S I I D D E E F F R R O O N N T T C C O O V V E E R R S S E E C C T T I I O O N N 1 1 : : G G E E N N E E R R A A T T O O R R F F U U N N[...]

TEST 9 - Check Brush Leads ...................................................... 43 TEST 10 - Check Brushes & Slip Rings ........................................ 43 TEST 11 - Check Rotor Assembly ................................................ 44 TEST 12 - Check Main Circuit Breaker .......................................... 44 TEST 13 - Chec[...]

S S e e c c t t i i o o n n 1 1 G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S S MA GNETISM 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 pat- terns of behavior that are kn[...]

S S e e c c t t i i o o n n 1 1 G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S S A SIMPLE A C GENERA T OR 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[...]

S S e e c c t t i i o o n n 1 1 G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S S 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[...]

S S e e c c t t i i o o n n 1 1 G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S S 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 al[...]

S S e e c c t t i i o o n n 1 1 G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S S Figure 1-8. – Connection for 120 Volts Only RECONNECTION FOR DUAL VOLTAGE OUTPUT: When connected for dual voltage output, Stator out- put leads 11P and 44 form two “hot” leads (T1- Red and T3- Black). The junction of leads 22P a[...]

S S e e c c t t i i o o n n 2 2 M M A A J J O O R R G G E E N N E E R R A A T T O O R R C C O O M M P P O O N N E E N N T T S S RO T OR ASSEMBL Y 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 cur[...]

S S e e c c t t i i o o n n 2 2 M M A A J J O O R R G G E E N N E E R R A A T T O O R R C C O O M M P P O O N N E E N N T T S S 3. Two excitation winding output leads (No. 2 and 6). These leads deliver unregulated excitation current to the voltage regulator. 4. Three (3) battery charge output leads (No. 55, 66 and 77). Figure 2-2. – Stator Output[...]

S S e e c c t t i i o o n n 2 2 M M A A J J O O R R G G E E N N E E R R A A T T O O R R C C O O M M P P O O N N E E N N T T S S 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) lea[...]

S S e e c c t t i i o o n n 2 2 M M A A J J O O R R G G E E N N E E R R A A T T O O R R C C O O M M P P O O N N E E N N T T S S elbow. The breather chamber contains a removable oil vapor collector. Oil vapor is condensed on the col- lector material and drains back into the crankcase, which minimizes the amount of oil vapor entering the breather. CH[...]

S S e e c c t t i i o o n n 3 3 I I N N S S U U L L A A T T I I O O N N R R E E S S I I S S T T A A N N C C E E T T E E S S T T S S 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 [...]

S S e e c c t t i i o o n n 3 3 I I N N S S U U L L A A T T I I O O N N R R E E S S I I S S T T A A N N C C E E T T E E S S T T S S C C A A U U T T I I O O N N ! ! : : S S o o m m e e g g e e n n e e r r a a t t o o r r s s m m a a y y u u s s e e e e p p o o x x y y o o r r p p o o l l y y e e s s t t e e r r b b a a s s e e w w i i n n d d i i n [...]

S S e e c c t t i i o o n n 3 3 I I N N S S U U L L A A T T I I O O N N R R E E S S I I S S T T A A N N C C E E T T E E S S T T S S 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 betwe[...]

S S e e c c t t i i o o n n 4 4 M M E E A A S S U U R R I I N N G G E E L L E E C C T T R R I I C C I I T T Y Y METERS 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 fre- quency, and (d) resistance In ohms. The following apply: ❏ To measure AC [...]

S S e e c c t t i i o o n n 4 4 M M E E A A S S U U R R I I N N G G E E L L E E C C T T R R I I C C I I T T Y Y MEASURING A C 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 180[...]

S S e e c c t t i i o o n n 4 4 M M E E A A S S U U R R I I N N G G E E L L E E C C T T R R I I C C I I T T Y Y 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 thou- sand [...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M 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. OPERA TION[...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M Page 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. [...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M Page 20 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 con- nected to frame Ground. Circuit board action w[...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M Page 21 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 BATT[...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M Page 22 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 Wi[...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M Page 23 CIRCUIT CONDITION- FAULT SHUTDOWN: The engine mounts a HIGH OIL TEMPERA- TURE SWITCH (HTO) and a LOW OIL PRES- SURE SWITCH (LOP). Should engine oil temperature exceed a pre- set value, the switch contacts will close. Wire 85 f[...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M ENGINE CONTROLLER CIRCUIT BO ARD GENERAL: The engine controller board is responsible for crank- ing, startup, running and shutdown operations. The board interconnects with other components of the DC control system to turn them on and [...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M The following chart applies: C C A A B B L L E E L L E E N N G G T T H H ( ( I I N N F F E E E E T T ) ) R R E E C C O O M M M M E E N N D D E E D D C C A A B B L L E E S S I I Z Z E E 0-10 No. 2 11-15 No. 0 16-20 No. 000 EFFECTS OF T[...]

S S e e c c t t i i o o n n 5 5 E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M 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. b. With Wire 17 ground[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S The “Flow Charts” 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 throu[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 28[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 29[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 30[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 31[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 32[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 33[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 34[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 35[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 36[...]

S S e e c c t t i i o o n n 6 6 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S Page 37[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S INTRODUCTION The “Diagnostic Tests” in this chapter may be per- formed 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 Invol[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 clock[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S PROCEDURE: 1. Disconnect Wire 4 from the Voltage Regulator (VR). (Third ter- minal from the top of VR). 2. Connect a jumper wire to Wire 4 and to the 12 volt fused battery positive supply Wire 15 (Wire 15 located at fuse (F1) holder). 3. Set the VOM to measu[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 a[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 sho[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 9. Connect the meter test leads across Stator lead 11P and frame ground. “Infinity” should be read. 10. Connect the meter test leads across Stator lead 33 and frame ground. The reading should be “Infinity”. 11. Connect the meter test leads across Sta[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 rec- ommended). b. After cleaning slip rings, blow away [...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 circu[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 BC[...]

Page 47 S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 3. In Step 7, if Wire 0 reads “Continuity”, but resistor does not measure 1 ohm, replace the Battery Charge Resistor. 4 . If all of the Steps in this test pass, perform “Insulation Resistance Test” on page 13. TEST 18 - TR Y CRANKING THE ENGI[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Figure 7-13. – The LPG Fuel Solenoid (FS) RESULTS: 1. If battery voltage is not indicated in Step 2, check Wire 15 between the Primer Switch and the 7.5 amp fuse for an open condition. 2 . If battery voltage is indicated in Step 2 but not in Step 4, replac[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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. Figure 7-15. – Harnes[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S RESULTS: 1 . If battery voltage is NOT indicated in Step 1, check continuity of: a . Wire 13 between Starter Contactor and Starter Contactor Relay. b. Wire 13 between Starter Contactor Relay and 7.5 Amp Fuse (F1). c. Wire 15 between the 7.5 Amp fuse (F1) and[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 Start- Stop Switch. 3. If the Start-Stop Switch (SW1) failed any part of Steps 5 or 6, replace the switch. 4. If engine will not cra[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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”, repl[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 con- nected to th[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Fi gu re 7- 24 . – Tachometer TEST BRACKET: A starter motor test bracket may be made as shown in Figure 7-25. Figure 7-25. – Test Bracket REMOVE STARTER MOTOR: It is recommended that the Starter Motor be removed from the engine when testing Starter Motor[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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.[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 [...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Figure 7-31. – Remote Harness Connector 3. Connect one test lead to Pin Location J1-15. Connect the other test lead to a clean frame ground. “Infinity” should be measured. RESULTS: 1. If “Continuity” is measured in Step 2, repair or replace shorted[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 cylin- der spark plug. 5. To determine if an engine miss is ignition related, [...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S TEST 33 - CHECK SP ARK 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. PROCEDURE: Remove spark plugs. Clean with a commerci[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Page 60 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 conn[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S measured. During cranking and running this read- ing 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[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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. TEST 36 -[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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, ti[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S TEST 38 - CHECK ENGINE / CYLINDER LEAK DO WN 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. ❏ Overheat[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 lev[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S Figure 7-48. – Testing Oil Temperature Switch RESULTS: 1. If the Oil Temperature Switch fails Step 3 or Step 4, replace the Oil Temperature Switch. 2. If the Oil Temperature Switch is good, an overheat condition may be occurring. Verify that the installati[...]

S S e e c c t t i i o o n n 7 7 D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S 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 Fue[...]

S S e e c c t t i i o o n n 8 8 A A S S S S E E M M B B L L Y Y MAJOR DISASSEMBL Y 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 & sid[...]

S S e e c c t t i i o o n n 8 8 A A S S S S E E M M B B L L Y Y 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. Perf[...]

S S e e c c t t i i o o n n 8 8 A A S S S S E E M M B B L L Y Y 8. Remove two (2) bolts holding blower housing on each cylinder head (a 10mm socket is required). 9. Loosen four (4) allen head bolts for intake manifold. Tilt mani- fold forward to gain clearance (using a 6mm allen wrench). 10. Remove blower housing. 1 1. Remove negative cable from st[...]

N N O O T T E E S S Page 71[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 72 Base & Pulley – Drawing No. 0E1323-A[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 73 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 1 0E0196 1 FRAME, 760 ENGINE 2 022129 12 WASHER LOCK M8-5/16 3 022145 15 WASHER FLAT 5/16-M8 ZINC 4 022259[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 74 Enclosure – Drawing No. 0E1011-B[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 75 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 1 0D8827 1 PANEL, ENCLOSURE ROOF 2 0A7215 22 SCREW SW 1/4-20X5/8 N WA JS500 3 029451 11.5 FT. TAPE ELEC UL[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 76 Sheet Metal – Drawing No. 0E1012-E[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 77 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 1 045756 15 SCREW HHTT M6-1.0 X 10 YC 2 0D1131 1 GUARD,FAN 12KW HSB 3 0C3022G 1 HOUSING, BLOWER V-TWIN RV [...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 78 Control Panel – Drawing No. 0E1013-A[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 79 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 1 0C2375 2 SCREW HHC M8-1.25 X 90 G8.8 2 022145 2 WASHER FLAT 5/16-M8 ZINC 3 029459 2 TENSION SPRING 4 075[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 80 760 V-Twin Engine – Drawing No. 0E1014-B[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 1 0C5730A 1 ASSEMBLY, CRANKCASE RV 2 0C3008 1 SEAL, 38 I.D. CRANKCASE 3 090388 6 SCREW, HHTT M6-1.0 X 12mm 4 0C537[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 82 LP Regulator – Drawing No. 0E1530[...]

S S e e c c t t i i o o n n 9 9 E E x x p p l l o o d d e e d d V V i i e e w w s s / / P P a a r r t t N N u u m m b b e e r r s s Page 83 I I T T E E M M P P A A R R T T N N O O . . Q Q T T Y Y . . D D E E S S C C R R I I P P T T I I O O N N 1 0D5694 1 CASTING, TWIN REGULATOR HOUSING 2 075475 4 SCREW PPHM M4-0.7 X 10 3 022264 4 WASHER LOCK #8-M4 [...]

S S e e c c t t i i o o n n 1 1 0 0 S S P P E E C C I I F F I I C C A A T T I I O O N N S S & & C C H H A A R R T T S S Page 84 Major Features and Dimensions – Drawing No. 0E1058-C[...]

S S e e c c t t i i o o n n 1 1 0 0 S S P P E E C C I I F F I I C C A A T T I I O O N N S S & & C C H H A A R R T T S S Page 85 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 12[...]

S S e e c c t t i i o o n n 1 1 0 0 S S P P E E C C I I F F I I C C A A T T I I O O N N S S & & C C H H A A R R T T S S Page 86 TORQUE SPECIFICA TIONS LONG BLOCK TORQUE REQUIREMENTS HEAD BOLTS 22 ft-lbs (±5%) SUMP COVER BOLTS 36 ft-lbs CONNECTING ROD CAP BOLTS 16.2 - 19.8 ft-lbs VALVE COVER BOLTS 4.8 - 5.5 ft-lbs ROCKER ARM JAM NUTS 156.6 [...]

N N O O T T E E S S Page 87[...]

S S e e c c t t i i o o n n 1 1 1 1 E E L L E E C C T T R R I I C C A A L L D D A A T T A A Page 88 Electrical Schematic and Wiring Diagram – Drawing No. 0E1057-D[...]

S S e e c c t t i i o o n n 1 1 1 1 E E L L E E C C T T R R I I C C A A L L D D A A T T A A Page 89 Electrical Schematic and Wiring Diagram – Drawing No. 0E1057-D[...]

PO BOX 297 WHITEWA TER, WI 53190 www .guardiangenerators.com P/N OE7225 REV O PRINTED IN THE USA/9.03[...]