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