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Generac Power Systems 65, 55, 75 manual Section Exploded Views / Part Numbers, 0C5730A

Models: 65 75 55

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Section 9

Exploded Views / Part Numbers

ITEM	PART NO. QTY.		DESCRIPTION		ITEM	PART NO. QTY.		DESCRIPTION
1	0C5730A	1	ASSEMBLY, CRANKCASE RV	33		0C2991	2	E-RING, GOVERNOR ARM
2	0C3008	1	SEAL, 38 I.D. CRANKCASE	34		0D1667A	1	ARM, GOVERNOR
3	090388	6	SCREW, HHTT M6-1.0 X 12mm	35		0C2988	1	THRUST WASHER, GOVERNOR
4	0C5372	1	ASSEMBLY, BREATHER	36		0C2992	1	BUSHING, GOVERNOR LOWER
5	0C3005	1	GASKET, BREATHER COVER	37		0C5732	1	ASSEMBLY, SUMP WITH SLEEVE
6	0C3003	3	SEPARATOR, OIL BREATHER	38		0C2993	1	SEAL, GOVERNOR SHAFT
7	0D8067A	1	ASSEMBLY, HEAD #1	39		0C3007	1	SEAL, 42 I.D. CRANKSHAFT
8	0C2981C	1	COVER, ROCKER	40		0D9756	1	CONNECTOR, 3/8NPT TO INVTD
9	071983	4	RETAINER, PISTON PIN 20					FLR 3/8OD
10	0C5848	2	PISTON, HC	41		0C3006	10	SCREW, HHFC M10-1.5 X 55mm
11	021533	2	SET, PISTON RING 90mm	42		0C8566	8	SCREW HHFC M6-1.0 X 20mm
12	071980	2	PIN , PISTON D20	43		0C2982	1	COVER, ROCKER WITH OIL FILL
13	0D4041	1	ASSEMBLY, CAMSHAFT & GEAR	44		093064	1	ASSEMBLY, OIL FILL CAP
14	0C2983	1	SHAFT, GOVERNOR	45		0C2979	2	GASKET, VALVE COVER
15A	0C2985A	2	ROLLER BEARING, GOVERNOR	46		086515	8	KEEPER, VALVE SPRING
			PLATE	47		0D2274	4	RETAINER, VALVE SPRING
15B	0C2985B	1	ROLLER BEARING, GOVERNOR	48		0D3867	4	SPRING, VALVE
16	0D4042	1	ASSEMBLY, GOVERNOR GEAR	49		078672	2	SEAL, VALVE STEM D7
17	0A7811	1	SPOOL, GOVERNOR MACHINED	50		0C5371	4	WASHER, VALVE SPRING
18	0C2977	1	GASKET, CRANK CASE	51		0D5326	4	NUT, JAM ROCKER ARM
19	0C5943	1	SEAL, OIL PASSAGE	52		0D5354	4	PIVOT, ROCKER ARM
20	0D4122A	1	ASSEMBLY, CRANKSHAFT	53		0D5313	4	ROCKER ARM
21	0D3961	2	ASSEMBLY, CONNECTING ROD	54		0D6023	4	STUD, ROCKER ARM M8-1.0 x
22	0C2978	2	GASKET, HEAD					57mm
23	093873	3	WASHER, LOCK RIB M6	55		0D6024	2	PLATE, PUSH ROD GUIDE
24	021374	3	SCREW, SHC M6-1.0 X 30mm	56		0C2976	12	SCREW HHFC M8-1.25 X 65mm
25	0C2994	1	SCREEN, OIL PICKUP	57		0D8067B	1	ASSEMBLY, HEAD #2
26	0C2997	1	COVER, GEROTOR	58		0C2229	2	VALVE, INTAKE
27	0C2995	1	GEROTOR, INNER	59		086516	2	VALVE, EXHAUST
28	0C2996	1	GEROTOR, OUTER	60		0D9853D	4	PUSHROD 147
29	0C3011	2	COVER, OIL RELIEF	61		083897	4	TAPPET, SOLID
30	0C3009	2	SPRING, OIL RELIEF	62		0C3017	1	STARTER, V-TWIN ENGINE
31	0C3010	2	BALL, 1/2D OIL RELIEF	63		022129	2	WASHER LOCK M8
32	050873A	1	1/4" NPT PIPE PLUG	64		061906	2	SCREW, HHC M8-1.25 X 85mm

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Generac Power Systems 65, 55, 75 manual Section Exploded Views / Part Numbers, 0C5730A

Contents

Model 4702, 4703, 4707, 4705, 4706, Diagnostic Repair ManualQUIETPACT 55/65/75 RECREATIONAL VEHICLE GENERATORNOTICE TO USERS OF THIS MANUAL SAFETYREPLACEMENT PARTS Table of Contents SECTION Table of ContentsELECTROMAGNETIC INDUCTION Section GENERATOR FUNDAMENTALSMAGNETISM ELECTROMAGNETIC FIELDSFigure 1-6.– A More Sophisticated Generator A SIMPLE AC GENERATORA MORE SOPHISTICATED AC GENERATOR Figure 1-5.– Alternating Current Sine WaveSection 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 OnlyFigure 2-1.Exploded View of Generator ROTOR ASSEMBLYSTATOR ASSEMBLY Section MAJOR GENERATOR COMPONENTSBRUSH HOLDER BATTERY CHARGE COMPONENTSFigure 2-4.– Battery Charge Circuit Figure 2-5.– Schematic: Excitation CircuitSection MAJOR GENERATOR COMPONENTS CRANKCASE BREATHERFigure 2-6.– Excitation Circuit Breaker Section MAJOR GENERATOR COMPONENTS CONTROL PANEL COMPONENT IDENTIFICATIONFigure 2-9.– Control Panel Components INSULATION RESISTANCE TESTERS CLEANING THE GENERATORSection INSULATION RESISTANCE TESTS EFFECTS OF DIRT AND MOISTURESection INSULATION RESISTANCE TESTS STATOR INSULATION RESISTANCEFigure 3-3.– Rotor Test Points TESTING ROTOR INSULATIONTHE MEGOHMMETER Figure 3-2.– Stator LeadsMEASURING AC VOLTAGE Section MEASURING ELECTRICITYMETERS THE VOMFigure 4-3.– A Line-Splitter MEASURING AC FREQUENCYMEASURING CURRENT MEASURING RESISTANCEAMPERES = VOLTSOHMS ELECTRICAL UNITSOHMS LAW FigureOPERATIONAL 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 SHUTDOWNFigure 5-2.- Receptacle J1 BATTERYENGINE CONTROLLER CIRCUIT BOARD Figure 5-3.– Engine Controller Circuit Board7.5 AMP FUSE FUEL PRIMER SWITCHSTART-STOPSWITCH Figure 5-5.– Primer Switch& STARTER MOTOR Figure 5-6.– Start-StopSwitchSection ENGINE DC CONTROL SYSTEM STARTER CONTACTOR RELAYINTRODUCTION 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 FLOWCHARTSTEST 2- CHECK ENGINE GOVERNOR Section DIAGNOSTIC TESTSFigure 7-1.– Governor Adjustment Points TEST 1- CHECK NO-LOADVOLTAGE AND FREQUENCYFigure 7-3.- Fixed Excitation Test TEST 3- TEST EXCITATION CIRCUIT BREAKERTEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW Figure 7-2.– Excitation “DPE” Circuit BreakerSection DIAGNOSTIC TESTS TEST 5- WIRE CONTINUITYFigure 7-5.– Stator Excitation Winding TEST 6- CHECK FIELD BOOSTTEST 7 - TEST STATOR DPE WINDING Figure 7-4.- The Field Boost CircuitSection DIAGNOSTIC TESTS TEST 8- CHECK SENSING LEADS / POWER WINDINGSFigure 7-7.– Brush Leads Figure 7-6.– Stator Power Winding LeadsTEST 9- CHECK BRUSH LEADS TEST 10 - CHECK BRUSHES & SLIP RINGSFigure 7-9.– Main Breaker Typical TEST 11- CHECK ROTOR ASSEMBLYFigure 7-8.– Rotor Assembly TEST 12 - CHECK MAIN CIRCUIT BREAKERTEST 14- CHECK LOAD WATTS & AMPERAGE TEST 15 - CHECK BATTERY CHARGE OUTPUTTEST 16 - CHECK BATTERY CHARGE RECTIFIER TEST 13- CHECK LOAD VOLTAGE & FREQUENCYSection DIAGNOSTIC TESTS TEST 17 - CHECK BATTERY CHARGEWINDINGS / BATTERY CHARGE RESISTOR Figure 7-10.- Battery Charge RectifierTEST 18 - TRY CRANKING THE ENGINE TEST 19- TEST PRIMER SWITCHFigure 7-11.– Primer Switch Figure 7-12.– Harness End of ConnectorSection DIAGNOSTIC TESTS TEST 20- CHECK FUEL PUMPFigure 7-13.- The LPG Fuel Solenoid FS Figure 7-14.– Electric Fuel PumpFigure 7-15.– Harness to Fuel Pump TEST 22- CHECK BATTERY & CABLESTEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD TEST 21- CHECK 7.5 AMP FUSESection DIAGNOSTIC TESTS TEST 24 - CHECK START-STOPSWITCHFigure 7-17.- Start-StopSwitch Figure 7-18.– Test 24, StepSection DIAGNOSTIC TESTS TEST 25 - CHECK POWER SUPPLY TO WIRETEST 26- CHECK STARTER CONTACTOR RELAY Figure 7-19.– Starter Contactor RelaySTEP 1 TEST POINT TEST 26A - CHECK STARTER CONTACTORTEST 27 - CHECK STARTER MOTOR Figure 7-20.– The Starter Contactor SCSection DIAGNOSTIC TESTS Figure 7-21.- Starter Motor SMFigure 7-22.- Check Pinion Gear Operation Section DIAGNOSTIC TESTS Figure 7-26.– Testing Starter Motor PerformanceTEST 28- CHECK FUEL SUPPLY Figure 7-24.– TachometerSection DIAGNOSTIC TESTS Figure 7-28– LP Gas Carburetion DiagramFigure 7-27- Typical Propane Gas Fuel System Figure 7-29.– Fuel Regulator TEST 29 - CHECK WIRE 14 POWER SUPPLYTEST 30 - CHECK WIRE Figure 7-30.– The 4-tabConnectorSection DIAGNOSTIC TESTS Figure 7-31.– Remote Harness ConnectorTEST 31 - CHECK FUEL SOLENOID GASOLINE MODELS TEST 32 - CHECK IGNITION SPARKSection DIAGNOSTIC TESTS Figure 7-32.– Testing Ignition SystemFigure 7-33.– Checking Engine Miss Figure 7-34.– Cylinder Balance TestTEST 33 - CHECK SPARK PLUGS TEST 34 - CHECK AND ADJUST IGNITION MAGNETOSFigure 7-35– Setting Spark Plug Gap Figure 7-36.– Ignition Magneto AssemblyFigure 7-39.– Diode Failure Diagnosis Figure 7-37.– Setting Ignition MagnetoArmature Air Gap Figure 7-38.– Engine Ground HarnessSection DIAGNOSTIC TESTS TEST 35 - CHECK VALVE ADJUSTMENTFigure 7-41– Adjusting Valve Clearance Figure 7-40.- Engine Ground Harness Test PointsSection DIAGNOSTIC TESTS TEST 36 - CHECK CARBURETIONTEST 37 - CHECK CHOKE SOLENOID Figure 7-42- Tightening the Jam NutSection DIAGNOSTIC TESTS Figure 7-43.- ConnectorFigure 7-44.– Exploded View of Choke Assembly Figure 7-45.– Automatic Choke AssemblySection DIAGNOSTIC TESTS DOWN TEST / COMPRESSION TESTTEST 38 - CHECK ENGINE / CYLINDER LEAK Figure 7-47.– Oil Temperature Switch TEST 39 - CHECK OIL PRESSURE SWITCHTEST 40 - TEST OIL TEMPERATURE SWITCH Figure 7-46.– Oil Pressure SwitchSection DIAGNOSTIC TESTS Figure 7-48.– Testing Oil Temperature SwitchTEST 41 - TEST CHOKE HEATER TEST 42 - CHECK LPG FUEL SOLENOIDSection 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 NumbersDESCRIPTION Section Exploded Views / Part NumbersITEM PART NO. QTYEnclosure – Drawing No. 0E1011-B Section Exploded Views / Part NumbersPART NO SectionExploded Views / Part Numbers ITEMSheet 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 Section SPECIFICATIONS & CHARTSGENERATOR SPECIFICATIONS NOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68FRV TORQUE REQUIREMENTS ENGINE SPEEDS AND VOLTAGE SPECIFICATIONSLONG BLOCK TORQUE REQUIREMENTS TRIM TORQUE REQUIREMENTSPage NOTESSection ELECTRICAL DATA Page Section ELECTRICAL DATAPRINTED IN THE USA/9.03 PO BOX 297 WHITEWATER, WIP/N OE7225 REV O