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Generac Power Systems 75, 55, 65 manual Table of Contents, Section

Models: 65 75 55

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Table of Contents

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 -
Check Load Voltage & Frequency	45
TEST 14 -
Check Load Watts & Amperage	45
TEST 15 -
Check Battery Charge Output	45
TEST 16 -
Check Battery Charge Rectifier	45
TEST 17 -
Check Battery Charge Windings/
Battery Charge Resistor	46
TEST 18 -
Try Cranking the Engine	47
TEST 19 -
Test Primer Switch	47
TEST 20 -
Check Fuel Pump	48
TEST 21 -
Check 7.5 Amp Fuse	49
TEST 22 -
Check Battery & Cables	49
TEST 23 -
Check Power Supply to Circuit Board	49
TEST 24 -
Check Start-Stop Switch	50
TEST 25 -
Check Power Supply to Wire 56	51
TEST 26 -
Check Starter Contactor Relay	51
TEST 26A -
Check Starter Contactor	52
TEST 27 -
Check Starter Motor	52
TEST 28 -
Check Fuel Supply	54
TEST 29 -
Check Wire 14 Power Supply	56
TEST 30 -
Check Wire 18	56
TEST 31 -
Check Fuel Solenoid
(Gasoline Models)	57
TEST 32 -
Check Ignition Spark	57
TEST 33 -
Check Spark Plugs	59
TEST 34 -
Check and Adjust Ignition Magnetos	59

TEST 35 -
Check Valve Adjustment	61
TEST 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
SECTION 8:
ASSEMBLY	68-70
MAJOR DISASSEMBLY	68
Enclosure/Panel Removal	68
Stator Removal	68
Rotor Removal	68
Belt Tensioning	69
Engine Removal	69
Startor Removal	69
Flywheel/Magneto Removal	70
SECTION 9:
EXPLODED VIEWS / PART NUMBERS	72-83
BASE & PULLEY DRAWING	72
ENCLOSURE DRAWING	74
SHEET METAL DRAWING	76
CONTROL PANEL DRAWING	78
760 V-TWIN ENGINE DRAWING	80
LP REGULATOR DRAWING	82
SECTION 10:
SPECIFICATIONS & CHARTS	84-86
MAJOR FEATURES AND DIMENSIONS	84
GENERATOR SPECIFICATIONS	85
NOMINAL RESISTANCES OF
GENERATOR WINDINGS AT 68°F	85
ENGINE SPEEDS AND
VOLTAGE SPECIFICATIONS	86
TORQUE SPECIFICATIONS	86
SECTION 11:
ELECTRICAL DATA	88-89
ELECTRICAL SCHEMATIC AND
WIRING DIAGRAM	88

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Generac Power Systems 75, 55, 65 manual Table of Contents, Section

Contents

Diagnostic Repair Manual QUIETPACT 55/65/75RECREATIONAL VEHICLE GENERATOR Model 4702, 4703, 4707, 4705, 4706,REPLACEMENT PARTS SAFETYNOTICE TO USERS OF THIS MANUAL Table of Contents Table of Contents SECTIONSection GENERATOR FUNDAMENTALS MAGNETISMELECTROMAGNETIC FIELDS ELECTROMAGNETIC INDUCTIONA SIMPLE AC GENERATOR A MORE SOPHISTICATED AC GENERATORFigure 1-5.– Alternating Current Sine Wave Figure 1-6.– A More Sophisticated GeneratorFigure 1-7.- Generator Operating Diagram Section GENERATOR FUNDAMENTALSGENERATOR AC CONNECTION SYSTEM FIELD BOOSTSection GENERATOR FUNDAMENTALS Figure 1-8.– Connection for 120 Volts Only Section GENERATOR FUNDAMENTALSROTOR ASSEMBLY STATOR ASSEMBLYSection MAJOR GENERATOR COMPONENTS Figure 2-1.Exploded View of GeneratorBATTERY CHARGE COMPONENTS Figure 2-4.– Battery Charge CircuitFigure 2-5.– Schematic: Excitation Circuit BRUSH HOLDERFigure 2-6.– Excitation Circuit Breaker CRANKCASE BREATHERSection MAJOR GENERATOR COMPONENTS Figure 2-9.– Control Panel Components CONTROL PANEL COMPONENT IDENTIFICATIONSection MAJOR GENERATOR COMPONENTS CLEANING THE GENERATOR Section INSULATION RESISTANCE TESTSEFFECTS OF DIRT AND MOISTURE INSULATION RESISTANCE TESTERSSTATOR INSULATION RESISTANCE Section INSULATION RESISTANCE TESTSTESTING ROTOR INSULATION THE MEGOHMMETERFigure 3-2.– Stator Leads Figure 3-3.– Rotor Test PointsSection MEASURING ELECTRICITY METERSTHE VOM MEASURING AC VOLTAGEMEASURING AC FREQUENCY MEASURING CURRENTMEASURING RESISTANCE Figure 4-3.– A Line-SplitterELECTRICAL UNITS OHMS LAWFigure AMPERES = VOLTSOHMSINTRODUCTION Section ENGINE DC CONTROL SYSTEMOPERATIONAL ANALYSIS CIRCUIT CONDITION- PRIMING Section ENGINE DC CONTROL SYSTEMPage Section ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- CRANKINGSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION-RUNNINGSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- SHUTDOWNCIRCUIT CONDITION- FAULT SHUTDOWN Section ENGINE DC CONTROL SYSTEMBATTERY ENGINE CONTROLLER CIRCUIT BOARDFigure 5-3.– Engine Controller Circuit Board Figure 5-2.- Receptacle J1FUEL PRIMER SWITCH START-STOPSWITCHFigure 5-5.– Primer Switch 7.5 AMP FUSEFigure 5-6.– Start-StopSwitch Section ENGINE DC CONTROL SYSTEMSTARTER CONTACTOR RELAY & STARTER MOTORSection TROUBLESHOOTING FLOWCHARTS INTRODUCTIONSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection DIAGNOSTIC TESTS Figure 7-1.– Governor Adjustment PointsTEST 1- CHECK NO-LOADVOLTAGE AND FREQUENCY TEST 2- CHECK ENGINE GOVERNORTEST 3- TEST EXCITATION CIRCUIT BREAKER TEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAWFigure 7-2.– Excitation “DPE” Circuit Breaker Figure 7-3.- Fixed Excitation TestTEST 5- WIRE CONTINUITY Section DIAGNOSTIC TESTSTEST 6- CHECK FIELD BOOST TEST 7 - TEST STATOR DPE WINDINGFigure 7-4.- The Field Boost Circuit Figure 7-5.– Stator Excitation WindingTEST 8- CHECK SENSING LEADS / POWER WINDINGS Section DIAGNOSTIC TESTSFigure 7-6.– Stator Power Winding Leads TEST 9- CHECK BRUSH LEADSTEST 10 - CHECK BRUSHES & SLIP RINGS Figure 7-7.– Brush LeadsTEST 11- CHECK ROTOR ASSEMBLY Figure 7-8.– Rotor AssemblyTEST 12 - CHECK MAIN CIRCUIT BREAKER Figure 7-9.– Main Breaker TypicalTEST 15 - CHECK BATTERY CHARGE OUTPUT TEST 16 - CHECK BATTERY CHARGE RECTIFIERTEST 13- CHECK LOAD VOLTAGE & FREQUENCY TEST 14- CHECK LOAD WATTS & AMPERAGETEST 17 - CHECK BATTERY CHARGE WINDINGS / BATTERY CHARGE RESISTORFigure 7-10.- Battery Charge Rectifier Section DIAGNOSTIC TESTSTEST 19- TEST PRIMER SWITCH Figure 7-11.– Primer SwitchFigure 7-12.– Harness End of Connector TEST 18 - TRY CRANKING THE ENGINETEST 20- CHECK FUEL PUMP Figure 7-13.- The LPG Fuel Solenoid FSFigure 7-14.– Electric Fuel Pump Section DIAGNOSTIC TESTSTEST 22- CHECK BATTERY & CABLES TEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARDTEST 21- CHECK 7.5 AMP FUSE Figure 7-15.– Harness to Fuel PumpTEST 24 - CHECK START-STOPSWITCH Figure 7-17.- Start-StopSwitchFigure 7-18.– Test 24, Step Section DIAGNOSTIC TESTSTEST 25 - CHECK POWER SUPPLY TO WIRE TEST 26- CHECK STARTER CONTACTOR RELAYFigure 7-19.– Starter Contactor Relay Section DIAGNOSTIC TESTSTEST 26A - CHECK STARTER CONTACTOR TEST 27 - CHECK STARTER MOTORFigure 7-20.– The Starter Contactor SC STEP 1 TEST POINTFigure 7-22.- Check Pinion Gear Operation Figure 7-21.- Starter Motor SMSection DIAGNOSTIC TESTS Figure 7-26.– Testing Starter Motor Performance TEST 28- CHECK FUEL SUPPLYFigure 7-24.– Tachometer Section DIAGNOSTIC TESTSFigure 7-27- Typical Propane Gas Fuel System Figure 7-28– LP Gas Carburetion DiagramSection DIAGNOSTIC TESTS TEST 29 - CHECK WIRE 14 POWER SUPPLY TEST 30 - CHECK WIREFigure 7-30.– The 4-tabConnector Figure 7-29.– Fuel RegulatorFigure 7-31.– Remote Harness Connector TEST 31 - CHECK FUEL SOLENOID GASOLINE MODELSTEST 32 - CHECK IGNITION SPARK Section DIAGNOSTIC TESTSFigure 7-32.– Testing Ignition System Figure 7-33.– Checking Engine MissFigure 7-34.– Cylinder Balance Test Section DIAGNOSTIC TESTSTEST 34 - CHECK AND ADJUST IGNITION MAGNETOS Figure 7-35– Setting Spark Plug GapFigure 7-36.– Ignition Magneto Assembly TEST 33 - CHECK SPARK PLUGSFigure 7-37.– Setting Ignition Magneto Armature Air GapFigure 7-38.– Engine Ground Harness Figure 7-39.– Diode Failure DiagnosisTEST 35 - CHECK VALVE ADJUSTMENT Figure 7-41– Adjusting Valve ClearanceFigure 7-40.- Engine Ground Harness Test Points Section DIAGNOSTIC TESTSTEST 36 - CHECK CARBURETION TEST 37 - CHECK CHOKE SOLENOIDFigure 7-42- Tightening the Jam Nut Section DIAGNOSTIC TESTSFigure 7-43.- Connector Figure 7-44.– Exploded View of Choke AssemblyFigure 7-45.– Automatic Choke Assembly Section DIAGNOSTIC TESTSTEST 38 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TESTSection DIAGNOSTIC TESTS TEST 39 - CHECK OIL PRESSURE SWITCH TEST 40 - TEST OIL TEMPERATURE SWITCHFigure 7-46.– Oil Pressure Switch Figure 7-47.– Oil Temperature SwitchFigure 7-48.– Testing Oil Temperature Switch TEST 41 - TEST CHOKE HEATERTEST 42 - CHECK LPG FUEL SOLENOID Section DIAGNOSTIC TESTSFigure 7-49.– Fuel Solenoid Section DIAGNOSTIC TESTSSection ASSEMBLY MAJOR DISASSEMBLYFigure 8-1.– Drive Belt Tension Section ASSEMBLYSection ASSEMBLY 10.Remove blower housingNOTES PageSection Exploded Views / Part Numbers Base & Pulley – Drawing No. 0E1323-ASection Exploded Views / Part Numbers ITEMPART NO. QTY DESCRIPTIONSection Exploded Views / Part Numbers Enclosure – Drawing No. 0E1011-BSection Exploded Views / Part NumbersITEM PART NOSection Exploded Views / Part Numbers Sheet Metal – Drawing No. 0E1012-ESection Exploded Views / Part Numbers ITEMSection Exploded Views / Part Numbers Control Panel - Drawing No. 0E1013-ASection Exploded Views / Part Numbers 0C2375Section Exploded Views / Part Numbers 760 V-TwinEngine – Drawing No. 0E1014-BSection Exploded Views / Part Numbers 0C5730ASection Exploded Views / Part Numbers LP Regulator - Drawing No. 0E1530Exploded Views / Part Numbers Section0D5694 Section SPECIFICATIONS & CHARTS SPECIFICATIONS & CHARTS GENERATOR SPECIFICATIONSNOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68F SectionENGINE SPEEDS AND VOLTAGE SPECIFICATIONS LONG BLOCK TORQUE REQUIREMENTSTRIM TORQUE REQUIREMENTS RV TORQUE REQUIREMENTSNOTES PageSection ELECTRICAL DATA Section ELECTRICAL DATA PageP/N OE7225 REV O PO BOX 297 WHITEWATER, WIPRINTED IN THE USA/9.03