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Guardian Quietpact 55 User Manual

Guardian Quietpact 55
92 pages
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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

Table of Contents

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Guardian Quietpact 55 Specifications

General IconGeneral
BrandGuardian
ModelQuietpact 55
CategoryPortable Generator
LanguageEnglish

Summary

Safety Information

Danger and Caution Alerts

Alerts for special instructions that could result in injury, death, or damage.

Notice to Users of This Manual

Assumes familiarity with servicing procedures and advises caution with non-recommended methods.

Replacement Parts Guidelines

Emphasizes using compliant parts and proper installation to prevent hazards.

Generator Fundamentals

Magnetism Principles

Explains the basic principles of magnetism and magnetic fields.

Electromagnetic Induction

Describes how voltage is generated by relative motion between conductors and magnetic fields.

Simple AC Generator Operation

Illustrates the basic components and alternating current generation.

Sophisticated AC Generator

Explains generators with regulated DC current to the rotor via brushes.

Field Boost Function

Details the role of field boost current in ensuring adequate startup voltage.

AC Connection System

Covers generator wiring for 120V and 120/240V loads.

Major Generator Components

Rotor and Stator Assemblies

Describes the rotor's magnetic field generation and stator's voltage induction.

Brush Holder and Slip Rings

Explains the function of brushes and slip rings in transferring excitation current.

Battery Charge and Excitation Circuits

Details components for battery charging and voltage regulation.

Voltage Regulator and Crankcase Breather

Explains voltage regulator operation and the crankcase breather system.

Control Panel Component Identification

Identifies major components located on the generator's control panel.

Insulation Resistance Tests

Effects of Dirt and Moisture

Discusses how contaminants degrade insulation and affect performance.

Insulation Testing Procedures

Details tests for stator and rotor insulation integrity and short-to-ground conditions.

Using a Megohmmeter

Explains the use of a megohmmeter for insulation resistance testing.

Measuring Electrical Quantities

Electrical Meters and VOM Usage

Introduces meters for measuring electrical properties and VOM usage.

Measuring AC Voltage and Frequency

Procedures for measuring AC output voltage and frequency accurately.

Measuring DC Voltage

Guidelines for measuring DC voltages, including polarity and scale settings.

Measuring Current and Resistance

Explains methods for measuring current and resistance to diagnose faults.

Electrical Units and Ohm's Law

Defines fundamental electrical units and explains Ohm's Law.

Engine DC Control System

System Overview and Operational States

Introduction to the DC system and analysis of its states (rest, priming, cranking, etc.).

Engine Controller Circuit Board

Details the functions, connections, and pinouts of the engine controller board.

Battery and Fuse Information

Provides battery recommendations and explains the 7.5 Amp fuse's role.

Primer and Start-Stop Switches

Explains the operation and function of primer and start-stop switches.

Starter Contactor Relay and Motor

Describes the starter relay and motor engagement for engine cranking.

Fault Shutdown Conditions

Details how oil pressure and temperature switches trigger engine shutdown.

Troubleshooting Flowcharts

Introduction to Troubleshooting

Guidance on using flowcharts and diagnostic tests for problem resolution.

AC Output Problems

Flowcharts for diagnosing issues with voltage, frequency, and output.

Engine Operation Problems

Flowcharts for diagnosing engine starting, running, and shutdown issues.

Fuse Blowing Troubleshooting

Flowchart to identify the cause of a repeatedly blowing 7.5A fuse.

Diagnostic Tests

No-Load Voltage and Frequency Check

Procedure to measure generator output voltage and frequency without load.

Engine Governor Adjustment

Steps for adjusting the engine governor to achieve correct speed and frequency.

Excitation Circuit Breaker Test

Tests the excitation circuit breaker for proper continuity and reset function.

Fixed Excitation and Rotor Amp Draw Test

Tests the excitation circuit and rotor by applying voltage and measuring current.

Wire Continuity and Field Boost Checks

Verifies wire continuity in voltage regulation and tests field boost function.

Stator and Rotor Winding Tests

Checks stator DPE, power windings, and rotor resistance for faults.

Brush and Slip Ring Inspection

Inspects brushes and slip rings for wear, damage, or contamination.

Main Circuit Breaker and Load Tests

Tests the main breaker and checks voltage/frequency under load.

Battery Charge System Tests

Tests battery charge output, rectifier, and windings resistance.

Fuel System Diagnostics

Tests primer switch, fuel pump, fuel solenoid, and supply for starting issues.

Ignition System and Cylinder Tests

Checks ignition spark, plugs, magnetos, and performs cylinder leak down/compression tests.

Oil Pressure and Temperature Switch Tests

Tests oil pressure and temperature switches for shutdown activation.

Choke Heater and LPG Fuel Solenoid Tests

Tests the choke heater and LPG fuel solenoid for proper operation.

Assembly Procedures

Major Disassembly Steps

Detailed instructions for disassembling enclosure, stator, rotor, and engine.

Belt Tensioning and Engine Removal

Procedures for drive belt tensioning and engine removal from the chassis.

Starter and Flywheel/Magneto Removal

Steps for removing the starter motor and the flywheel/magneto assembly.

Exploded Views and Part Numbers

Base and Pulley Assembly

Exploded view of the generator base and pulley system with part identification.

Generator Sheet Metal Components

Exploded view detailing the various sheet metal parts of the generator.

Control Panel Assembly

Exploded view illustrating the components of the generator's control panel.

LP Regulator Assembly

Exploded view of the LP regulator showing its parts and assembly.

Specifications and Charts

Generator Technical Specifications

Lists key specifications for QuietPact 55, 65, and 75 generator models.

Generator Winding Resistances

Provides nominal resistance values for generator windings at 68°F.

Engine Speed and Voltage Specifications

Details expected engine speeds, voltages, and frequencies under varying loads.

Torque Specifications

Lists essential torque values for engine and generator assembly fasteners.

Electrical Data

Electrical Schematic and Wiring Diagram

Presents the complete electrical schematic and wiring diagram for the generator.

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