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55, 75, 65 manual Section Exploded Views / Part Numbers
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Troubleshooting
Specification
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
Page 78
Image 78
Section 9
Exploded Views / Part Numbers
Sheet Metal – Drawing No.
0E1012-E
Page 76
Page 77
Page 79
Page 78
Image 78
Page 77
Page 79
Contents
RECREATIONAL VEHICLE GENERATOR
Diagnostic Repair Manual
QUIETPACT 55/65/75
Model 4702, 4703, 4707, 4705, 4706,
SAFETY
REPLACEMENT PARTS
NOTICE TO USERS OF THIS MANUAL
Table of Contents
Table of Contents
SECTION
ELECTROMAGNETIC FIELDS
Section GENERATOR FUNDAMENTALS
MAGNETISM
ELECTROMAGNETIC INDUCTION
Figure 1-5.– Alternating Current Sine Wave
A SIMPLE AC GENERATOR
A MORE SOPHISTICATED AC GENERATOR
Figure 1-6.– A More Sophisticated Generator
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
Section GENERATOR FUNDAMENTALS
Section MAJOR GENERATOR COMPONENTS
ROTOR ASSEMBLY
STATOR ASSEMBLY
Figure 2-1.Exploded View of Generator
Figure 2-5.– Schematic: Excitation Circuit
BATTERY CHARGE COMPONENTS
Figure 2-4.– Battery Charge Circuit
BRUSH HOLDER
CRANKCASE BREATHER
Figure 2-6.– Excitation Circuit Breaker
Section MAJOR GENERATOR COMPONENTS
CONTROL PANEL COMPONENT IDENTIFICATION
Figure 2-9.– Control Panel Components
Section MAJOR GENERATOR COMPONENTS
EFFECTS OF DIRT AND MOISTURE
CLEANING THE GENERATOR
Section INSULATION RESISTANCE TESTS
INSULATION RESISTANCE TESTERS
STATOR INSULATION RESISTANCE
Section INSULATION RESISTANCE TESTS
Figure 3-2.– Stator Leads
TESTING ROTOR INSULATION
THE MEGOHMMETER
Figure 3-3.– Rotor Test Points
THE VOM
Section MEASURING ELECTRICITY
METERS
MEASURING AC VOLTAGE
MEASURING RESISTANCE
MEASURING AC FREQUENCY
MEASURING CURRENT
Figure 4-3.– A Line-Splitter
Figure
ELECTRICAL UNITS
OHMS LAW
AMPERES = VOLTSOHMS
Section ENGINE DC CONTROL SYSTEM
INTRODUCTION
OPERATIONAL ANALYSIS
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- PRIMING
Page
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- CRANKING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION-RUNNING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- SHUTDOWN
CIRCUIT CONDITION- FAULT SHUTDOWN
Section ENGINE DC CONTROL SYSTEM
Figure 5-3.– Engine Controller Circuit Board
BATTERY
ENGINE CONTROLLER CIRCUIT BOARD
Figure 5-2.- Receptacle J1
Figure 5-5.– Primer Switch
FUEL PRIMER SWITCH
START-STOPSWITCH
7.5 AMP FUSE
STARTER CONTACTOR RELAY
Figure 5-6.– Start-StopSwitch
Section ENGINE DC CONTROL SYSTEM
& STARTER MOTOR
Section TROUBLESHOOTING FLOWCHARTS
INTRODUCTION
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
TEST 1- CHECK NO-LOADVOLTAGE AND FREQUENCY
Section DIAGNOSTIC TESTS
Figure 7-1.– Governor Adjustment Points
TEST 2- CHECK ENGINE GOVERNOR
Figure 7-2.– Excitation “DPE” Circuit Breaker
TEST 3- TEST EXCITATION CIRCUIT BREAKER
TEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW
Figure 7-3.- Fixed Excitation Test
TEST 5- WIRE CONTINUITY
Section DIAGNOSTIC TESTS
Figure 7-4.- The Field Boost Circuit
TEST 6- CHECK FIELD BOOST
TEST 7 - TEST STATOR DPE WINDING
Figure 7-5.– Stator Excitation Winding
TEST 8- CHECK SENSING LEADS / POWER WINDINGS
Section DIAGNOSTIC TESTS
TEST 10 - CHECK BRUSHES & SLIP RINGS
Figure 7-6.– Stator Power Winding Leads
TEST 9- CHECK BRUSH LEADS
Figure 7-7.– Brush Leads
TEST 12 - CHECK MAIN CIRCUIT BREAKER
TEST 11- CHECK ROTOR ASSEMBLY
Figure 7-8.– Rotor Assembly
Figure 7-9.– Main Breaker Typical
TEST 13- CHECK LOAD VOLTAGE & FREQUENCY
TEST 15 - CHECK BATTERY CHARGE OUTPUT
TEST 16 - CHECK BATTERY CHARGE RECTIFIER
TEST 14- CHECK LOAD WATTS & AMPERAGE
Figure 7-10.- Battery Charge Rectifier
TEST 17 - CHECK BATTERY CHARGE
WINDINGS / BATTERY CHARGE RESISTOR
Section DIAGNOSTIC TESTS
Figure 7-12.– Harness End of Connector
TEST 19- TEST PRIMER SWITCH
Figure 7-11.– Primer Switch
TEST 18 - TRY CRANKING THE ENGINE
Figure 7-14.– Electric Fuel Pump
TEST 20- CHECK FUEL PUMP
Figure 7-13.- The LPG Fuel Solenoid FS
Section DIAGNOSTIC TESTS
TEST 21- CHECK 7.5 AMP FUSE
TEST 22- CHECK BATTERY & CABLES
TEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD
Figure 7-15.– Harness to Fuel Pump
Figure 7-18.– Test 24, Step
TEST 24 - CHECK START-STOPSWITCH
Figure 7-17.- Start-StopSwitch
Section DIAGNOSTIC TESTS
Figure 7-19.– Starter Contactor Relay
TEST 25 - CHECK POWER SUPPLY TO WIRE
TEST 26- CHECK STARTER CONTACTOR RELAY
Section DIAGNOSTIC TESTS
Figure 7-20.– The Starter Contactor SC
TEST 26A - CHECK STARTER CONTACTOR
TEST 27 - CHECK STARTER MOTOR
STEP 1 TEST POINT
Figure 7-21.- Starter Motor SM
Figure 7-22.- Check Pinion Gear Operation
Section DIAGNOSTIC TESTS
Figure 7-24.– Tachometer
Figure 7-26.– Testing Starter Motor Performance
TEST 28- CHECK FUEL SUPPLY
Section DIAGNOSTIC TESTS
Figure 7-28– LP Gas Carburetion Diagram
Figure 7-27- Typical Propane Gas Fuel System
Section DIAGNOSTIC TESTS
Figure 7-30.– The 4-tabConnector
TEST 29 - CHECK WIRE 14 POWER SUPPLY
TEST 30 - CHECK WIRE
Figure 7-29.– Fuel Regulator
TEST 32 - CHECK IGNITION SPARK
Figure 7-31.– Remote Harness Connector
TEST 31 - CHECK FUEL SOLENOID GASOLINE MODELS
Section DIAGNOSTIC TESTS
Figure 7-34.– Cylinder Balance Test
Figure 7-32.– Testing Ignition System
Figure 7-33.– Checking Engine Miss
Section DIAGNOSTIC TESTS
Figure 7-36.– Ignition Magneto Assembly
TEST 34 - CHECK AND ADJUST IGNITION MAGNETOS
Figure 7-35– Setting Spark Plug Gap
TEST 33 - CHECK SPARK PLUGS
Figure 7-38.– Engine Ground Harness
Figure 7-37.– Setting Ignition Magneto
Armature Air Gap
Figure 7-39.– Diode Failure Diagnosis
Figure 7-40.- Engine Ground Harness Test Points
TEST 35 - CHECK VALVE ADJUSTMENT
Figure 7-41– Adjusting Valve Clearance
Section DIAGNOSTIC TESTS
Figure 7-42- Tightening the Jam Nut
TEST 36 - CHECK CARBURETION
TEST 37 - CHECK CHOKE SOLENOID
Section DIAGNOSTIC TESTS
Figure 7-45.– Automatic Choke Assembly
Figure 7-43.- Connector
Figure 7-44.– Exploded View of Choke Assembly
Section DIAGNOSTIC TESTS
DOWN TEST / COMPRESSION TEST
TEST 38 - CHECK ENGINE / CYLINDER LEAK
Section DIAGNOSTIC TESTS
Figure 7-46.– Oil Pressure Switch
TEST 39 - CHECK OIL PRESSURE SWITCH
TEST 40 - TEST OIL TEMPERATURE SWITCH
Figure 7-47.– Oil Temperature Switch
TEST 42 - CHECK LPG FUEL SOLENOID
Figure 7-48.– Testing Oil Temperature Switch
TEST 41 - TEST CHOKE HEATER
Section DIAGNOSTIC TESTS
Figure 7-49.– Fuel Solenoid
Section DIAGNOSTIC TESTS
Section ASSEMBLY
MAJOR DISASSEMBLY
Figure 8-1.– Drive Belt Tension
Section ASSEMBLY
Section ASSEMBLY
10.Remove blower housing
NOTES
Page
Section Exploded Views / Part Numbers
Base & Pulley – Drawing No. 0E1323-A
PART NO. QTY
Section Exploded Views / Part Numbers
ITEM
DESCRIPTION
Section Exploded Views / Part Numbers
Enclosure – Drawing No. 0E1011-B
ITEM
Section
Exploded Views / Part Numbers
PART NO
Section Exploded Views / Part Numbers
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 SPECIFICATIONS & CHARTS
NOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68F
SPECIFICATIONS & CHARTS
GENERATOR SPECIFICATIONS
Section
TRIM TORQUE REQUIREMENTS
ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS
LONG BLOCK TORQUE REQUIREMENTS
RV TORQUE REQUIREMENTS
NOTES
Page
Section ELECTRICAL DATA
Section ELECTRICAL DATA
Page
PO BOX 297 WHITEWATER, WI
P/N OE7225 REV O
PRINTED IN THE USA/9.03
