Manuals / Generac Power Systems / Lawn and Garden / Portable Generator

Generac Power Systems 65, 55 Section, Exploded Views / Part Numbers, Item, Part No, Description

Models: 65 75 55

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				Section 9
				Exploded Views / Part Numbers


	ITEM	PART NO.	QTY.	DESCRIPTION
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 FOAM 1/8 X 1/2"
4		0D8825	1	PANEL, SIDE AND BACK ENCLOSURE
5		0D3700	14	NUT FLANGE M6-1.0 NYLOK (GASOLINE ONLY)
		0D3700	17	NUT FLANGE M6-1.0 NYLOK (LP ONLY)
6		090388	8	SCREW HHTT M6-1.0 X 12 YC
7		0D8979	1	PANEL, AIR IN DUCT BASE
8		0D8960	1	PANEL, CUSTOMER CONNECTION
9		023484D	1	BUSHING SNAP SB-875-11
10		0E0594	1	COVER, RV AIR CLEANER BOX
11		064113	1	STUD WINGNUT M6-1.0 X 20MM NY
12		0E0575	1	FOAM SEALING STRIP 1" X 12FT
13		0D8980	1	PANEL, AIR IN DUCT BACK
14		0E1376	1	BAFFLE, V-TWIN RV SHORT
15		0E1377	1	BAFFLE, V-TWIN RV LONG
16		0D8628	3.5	FOAM, AIR OUT COMPARTMENT
17		0D8910	1	PANEL, MUFFLER SHIELD
18		0D8826	1	PANEL, ENCLOSURE SIDE
19		0D9162	1	PANEL, FRONT & SIDE ENCLOSURE
20		0C5644	2	SLIDE LATCH,FLUSH
21		0D8828	1	PANEL, ENCLOSURE DOOR
22		0E0585	1	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	WASHER LOCK 3/8
32		0C7423	1	STUD 3/8-16 X 2-1/4 BRASS
33		0742600151	1	GND WIRE C/PNL TO STUD V-T RV
34		0A4456	1	WASHER LOCK SPECIAL 3/8
35		0D8502	1	NEUTRAL CONNETCTOR UL
36		0E0593	1	STUD, 1/4-20 TO 5/16-18
37		0742600148	1	WIRE ASM BATT. (POS.) QP RV
38		022129	2	WASHER LOCK M8-5/16 (GASOLINE ONLY)
		022129	4	WASHER LOCK M8-5/16 (LP ONLY)
39		022259	2	NUT HEX 5/16-18 STEEL
40		045756	8	SCREW HHTT M6-1.0 X 10 YC
41		0A2115	1	WASHER NYLON .250
42		029451A	6.5 FT.	TAPE, 1/2" X 1/16" CLOSED CELL
43		0E1534A	1	PLUG PLASTIC 1.50" (GASOLINE ONLY)
44		0A5606	1	ELBOW 90DEG 3/8X3/4 (LP ONLY)
45		0E1528	1	BRACKET, LP REGULATOR MOUNTING (LP ONLY)
46		0A1495	2	SCREW HHTT M4-0.7 X 10 BP (LP ONLY)
47		042907	2	SCREW HHC M8-1.25 X 16 G8.8 (LP ONLY)
48		022145	1	WASHER FLAT 5/16-M8 ZINC (GASOLINE ONLY)
		022145	3	WASHER FLAT 5/16-M8 ZINC (LP ONLY)
49		0D8979A	1	PANEL, AIR IN DUCT

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Generac Power Systems 65, 55, 75 manual Section, Exploded Views / Part Numbers, Item, Part No, Description

Contents

QUIETPACT 55/65/75 Diagnostic Repair ManualRECREATIONAL VEHICLE GENERATOR Model 4702, 4703, 4707, 4705, 4706,NOTICE TO USERS OF THIS MANUAL SAFETYREPLACEMENT PARTS Table of Contents SECTION Table of ContentsMAGNETISM Section GENERATOR FUNDAMENTALSELECTROMAGNETIC FIELDS ELECTROMAGNETIC INDUCTIONA MORE SOPHISTICATED AC GENERATOR A SIMPLE AC GENERATORFigure 1-5.– Alternating Current Sine Wave Figure 1-6.– A More Sophisticated GeneratorSection GENERATOR FUNDAMENTALS Figure 1-7.- Generator Operating DiagramSection GENERATOR FUNDAMENTALS FIELD BOOSTGENERATOR AC CONNECTION SYSTEM Section GENERATOR FUNDAMENTALS Figure 1-8.– Connection for 120 Volts OnlySTATOR ASSEMBLY ROTOR ASSEMBLYSection MAJOR GENERATOR COMPONENTS Figure 2-1.Exploded View of GeneratorFigure 2-4.– Battery Charge Circuit BATTERY CHARGE COMPONENTSFigure 2-5.– Schematic: Excitation Circuit BRUSH HOLDERSection MAJOR GENERATOR COMPONENTS CRANKCASE BREATHERFigure 2-6.– Excitation Circuit Breaker Section MAJOR GENERATOR COMPONENTS CONTROL PANEL COMPONENT IDENTIFICATIONFigure 2-9.– Control Panel Components Section INSULATION RESISTANCE TESTS CLEANING THE GENERATOREFFECTS OF DIRT AND MOISTURE INSULATION RESISTANCE TESTERSSection INSULATION RESISTANCE TESTS STATOR INSULATION RESISTANCETHE MEGOHMMETER TESTING ROTOR INSULATIONFigure 3-2.– Stator Leads Figure 3-3.– Rotor Test PointsMETERS Section MEASURING ELECTRICITYTHE VOM MEASURING AC VOLTAGEMEASURING CURRENT MEASURING AC FREQUENCYMEASURING RESISTANCE Figure 4-3.– A Line-SplitterOHMS LAW ELECTRICAL UNITSFigure AMPERES = VOLTSOHMSOPERATIONAL ANALYSIS Section ENGINE DC CONTROL SYSTEMINTRODUCTION Page Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION- PRIMING CIRCUIT CONDITION- CRANKING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION-RUNNING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION- SHUTDOWN Section ENGINE DC CONTROL SYSTEMSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- FAULT SHUTDOWNENGINE CONTROLLER CIRCUIT BOARD BATTERYFigure 5-3.– Engine Controller Circuit Board Figure 5-2.- Receptacle J1START-STOPSWITCH FUEL PRIMER SWITCHFigure 5-5.– Primer Switch 7.5 AMP FUSESection ENGINE DC CONTROL SYSTEM Figure 5-6.– Start-StopSwitchSTARTER CONTACTOR RELAY & STARTER MOTORINTRODUCTION Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSFigure 7-1.– Governor Adjustment Points Section DIAGNOSTIC TESTSTEST 1- CHECK NO-LOADVOLTAGE AND FREQUENCY TEST 2- CHECK ENGINE GOVERNORTEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW TEST 3- TEST EXCITATION CIRCUIT BREAKERFigure 7-2.– Excitation “DPE” Circuit Breaker Figure 7-3.- Fixed Excitation TestSection DIAGNOSTIC TESTS TEST 5- WIRE CONTINUITYTEST 7 - TEST STATOR DPE WINDING TEST 6- CHECK FIELD BOOSTFigure 7-4.- The Field Boost Circuit Figure 7-5.– Stator Excitation WindingSection DIAGNOSTIC TESTS TEST 8- CHECK SENSING LEADS / POWER WINDINGSTEST 9- CHECK BRUSH LEADS Figure 7-6.– Stator Power Winding LeadsTEST 10 - CHECK BRUSHES & SLIP RINGS Figure 7-7.– Brush LeadsFigure 7-8.– Rotor Assembly TEST 11- CHECK ROTOR ASSEMBLYTEST 12 - CHECK MAIN CIRCUIT BREAKER Figure 7-9.– Main Breaker TypicalTEST 16 - CHECK BATTERY CHARGE RECTIFIER TEST 15 - CHECK BATTERY CHARGE OUTPUTTEST 13- CHECK LOAD VOLTAGE & FREQUENCY TEST 14- CHECK LOAD WATTS & AMPERAGEWINDINGS / BATTERY CHARGE RESISTOR TEST 17 - CHECK BATTERY CHARGEFigure 7-10.- Battery Charge Rectifier Section DIAGNOSTIC TESTSFigure 7-11.– Primer Switch TEST 19- TEST PRIMER SWITCHFigure 7-12.– Harness End of Connector TEST 18 - TRY CRANKING THE ENGINEFigure 7-13.- The LPG Fuel Solenoid FS TEST 20- CHECK FUEL PUMPFigure 7-14.– Electric Fuel Pump Section DIAGNOSTIC TESTSTEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD TEST 22- CHECK BATTERY & CABLESTEST 21- CHECK 7.5 AMP FUSE Figure 7-15.– Harness to Fuel PumpFigure 7-17.- Start-StopSwitch TEST 24 - CHECK START-STOPSWITCHFigure 7-18.– Test 24, Step Section DIAGNOSTIC TESTSTEST 26- CHECK STARTER CONTACTOR RELAY TEST 25 - CHECK POWER SUPPLY TO WIREFigure 7-19.– Starter Contactor Relay Section DIAGNOSTIC TESTSTEST 27 - CHECK STARTER MOTOR TEST 26A - CHECK STARTER CONTACTORFigure 7-20.– The Starter Contactor SC STEP 1 TEST POINTSection DIAGNOSTIC TESTS Figure 7-21.- Starter Motor SMFigure 7-22.- Check Pinion Gear Operation TEST 28- CHECK FUEL SUPPLY Figure 7-26.– Testing Starter Motor PerformanceFigure 7-24.– Tachometer Section DIAGNOSTIC TESTSSection DIAGNOSTIC TESTS Figure 7-28– LP Gas Carburetion DiagramFigure 7-27- Typical Propane Gas Fuel System TEST 30 - CHECK WIRE TEST 29 - CHECK WIRE 14 POWER SUPPLYFigure 7-30.– The 4-tabConnector Figure 7-29.– Fuel RegulatorTEST 31 - CHECK FUEL SOLENOID GASOLINE MODELS Figure 7-31.– Remote Harness ConnectorTEST 32 - CHECK IGNITION SPARK Section DIAGNOSTIC TESTSFigure 7-33.– Checking Engine Miss Figure 7-32.– Testing Ignition SystemFigure 7-34.– Cylinder Balance Test Section DIAGNOSTIC TESTSFigure 7-35– Setting Spark Plug Gap TEST 34 - CHECK AND ADJUST IGNITION MAGNETOSFigure 7-36.– Ignition Magneto Assembly TEST 33 - CHECK SPARK PLUGSArmature Air Gap Figure 7-37.– Setting Ignition MagnetoFigure 7-38.– Engine Ground Harness Figure 7-39.– Diode Failure DiagnosisFigure 7-41– Adjusting Valve Clearance TEST 35 - CHECK VALVE ADJUSTMENTFigure 7-40.- Engine Ground Harness Test Points Section DIAGNOSTIC TESTSTEST 37 - CHECK CHOKE SOLENOID TEST 36 - CHECK CARBURETIONFigure 7-42- Tightening the Jam Nut Section DIAGNOSTIC TESTSFigure 7-44.– Exploded View of Choke Assembly Figure 7-43.- ConnectorFigure 7-45.– Automatic Choke Assembly Section DIAGNOSTIC TESTSSection DIAGNOSTIC TESTS DOWN TEST / COMPRESSION TESTTEST 38 - CHECK ENGINE / CYLINDER LEAK TEST 40 - TEST OIL TEMPERATURE SWITCH TEST 39 - CHECK OIL PRESSURE SWITCHFigure 7-46.– Oil Pressure Switch Figure 7-47.– Oil Temperature SwitchTEST 41 - TEST CHOKE HEATER Figure 7-48.– Testing Oil Temperature SwitchTEST 42 - CHECK LPG FUEL SOLENOID Section DIAGNOSTIC TESTSSection DIAGNOSTIC TESTS Figure 7-49.– Fuel SolenoidMAJOR DISASSEMBLY Section ASSEMBLYSection ASSEMBLY Figure 8-1.– Drive Belt Tension10.Remove blower housing Section ASSEMBLYPage NOTESBase & Pulley – Drawing No. 0E1323-A Section Exploded Views / Part NumbersITEM Section Exploded Views / Part NumbersPART NO. QTY DESCRIPTIONEnclosure – Drawing No. 0E1011-B Section Exploded Views / Part NumbersExploded Views / Part Numbers SectionITEM PART NOSheet Metal – Drawing No. 0E1012-E Section Exploded Views / Part NumbersITEM Section Exploded Views / Part NumbersControl Panel - Drawing No. 0E1013-A Section Exploded Views / Part Numbers0C2375 Section Exploded Views / Part Numbers760 V-TwinEngine – Drawing No. 0E1014-B Section Exploded Views / Part Numbers0C5730A Section Exploded Views / Part NumbersLP Regulator - Drawing No. 0E1530 Section Exploded Views / Part Numbers0D5694 SectionExploded Views / Part Numbers Section SPECIFICATIONS & CHARTS GENERATOR SPECIFICATIONS SPECIFICATIONS & CHARTSNOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68F SectionLONG BLOCK TORQUE REQUIREMENTS ENGINE SPEEDS AND VOLTAGE SPECIFICATIONSTRIM TORQUE REQUIREMENTS RV TORQUE REQUIREMENTSPage NOTESSection ELECTRICAL DATA Page Section ELECTRICAL DATAPRINTED IN THE USA/9.03 PO BOX 297 WHITEWATER, WIP/N OE7225 REV O