Diagnostic Repair Manual
 Safety
Replacement Parts
 Table of Contents
 57-59
 Magnetism
Electromagnetic Fields
Electromagnetic Induction
 Simple AC Generator
More Sophisticated AC Generator
 Generator Operating Diagram
 Field Boost
Generator AC Connection System
Line Breakers 120 VAC only
 Connection for 120/240 VAC Dual Voltage
 Rotor Assembly
LIC Grit or Abrasive to Clean Slip Rings
 Battery Charge Components
Brush Holder
Excitation Circuit Components
General
 Adjust POT LED
Adjustment Procedure
162
Voltage Regulator
 Control Panel Component Identification
Control Panel Components
 Cleaning the Generator
Effects of Dirt and Moisture
Drying the Generator
Insulation Resistance Testers
 Brushing and Vacuum Cleaning
Stator Insulation Resistance
Cloth or Compressed AIR
Stator SHORT-TO-GROUND Tests
 Testing Rotor Insulation
Megohmmeter
 Meters
VOM
Measuring AC Voltage
Measuring DC Voltage
 Measuring AC Frequency
Measuring Current
Measuring Resistance
 Electrical Units
Ohms LAW
 Introduction
Operational Analysis
Circuit CONDITION- OFF
 Circuit CONDITION- PRE-HEAT
 Circuit CONDITION- Cranking
 Circuit CONDITION-RUNNING
 Circuit CONDITION- Shutdown
 Circuit CONDITION- Fault Shutdowns
 Battery
Engine Control Circuit Board
 Effects of Temperature
Checking Battery State of Charge
Charging a Battery
Adding Water
 Preheat Switch
START/STOP Switch
AMP Fuse
Starter Contactor & Motor
 Engine Governor
Fuel Injection Pump
Fuel NOZZLES/INJECTORS
Glow Plugs
 LOW OIL Pressure Switch High Coolant Temperature Switch
Adapter LOW OIL Pressure Switch
Engine Protective Devices
Overspeed Protection
 Troubleshooting Flowcharts
 Troubleshooting Flowcharts
 Problem 3 No Battery Charge Output
 Troubleshooting Flowcharts
 Troubleshooting Flowcharts
 Troubleshooting Flowcharts
 Troubleshooting Flowcharts
 Troubleshooting Flowcharts
 Test 2 Check & Adjust
Test 1- Check NO-LOAD Voltage Frequency
 Test 3- Test Excitation Circuit Breaker
Test 4- Fixed Excitation TEST/ROTOR AMP Draw
 Test 5- Wire Continuity
Re-connect Wire 11 and Wire 22 to the Voltage Regulator
Test 6- Check Field Boost
Set a VOM to its Rx1 scale
 Test 7 Test Stator DPE Winding
Model QP75D
 Test 8- Check Sensing Leads / Power Windings
Test 9- Check Brush Leads
159W
184W
 Test 11- Check Rotor Assembly
Tance Tests Procedure
Test 10 Check Brushes & Slip Rings
 Test 15 Check Battery Charge Output
Test 12 Check Main Circuit Breaker
Test 13- Check Load Voltage Frequency
Test 14- Check Load Watts & Amperage
 Test 16 Check Battery Charge Rectifier
Battery Charge Rectifier BCR is a full wave rectifier
Short to Ground
 Test 19- Test PRE-HEAT Switch
Set a VOM to read battery voltage 12 VDC
Test 18 TRY Cranking the Engine
Test 20- Check Fuel Pump
 Test 22- Check Battery & Cables
Test 23- Check Power Supply to Circuit Board
Disconnect the connector from the wires of the fuel pump
Test 21- Check 14 AMP Fuse
 Test 24 Check START-STOP Switch
Not Activated
 Test 26- Test Starter Contactor
Test 27 Check Starter Motor
Conditions Affecting Starter Motor Performance
 Checking the Pinion
Pinion
Tools for Starter Performance Test
Measuring Current
 Testing Starter Motor
Tachometer
Test Bracket
Starter motor test bracket may be made as shown in Figure
 Test 29 Check Wire 14 Power Supply
Test 30 Check Wire
If Wire 18 checks GOOD, proceed to Problem 8 Section
Test 28- Check Fuel Supply
 Test 32- Test Preheat Contactor
Test 33- Test Glow Plugs
Test 34- Test D1 Diode
 Test 35- Check Valve Adjustment
Remove the valve cover from engine Disconnect the battery
Test 36- Fuel Injector Pump
 If fuel is noted, proceed to next step in flowchart
Adjust the regulated pressure on the gauge to 80 psi
Down Test / Compression Test
Repeat Steps 1 through 8 on remaining cylinder
 Test 38 Check OIL Pressure Switch
Test 40- Test Water Temperature Switch
Test 39- Check Circuit Board for Ground
 Test 43 Check Wire 15 for Short to Ground
If continuity is measure, replace the switch
Components for Short to Ground
 Major Disassembly
 RE-ASSEMBLY
Belt Tensioning
 Line Corner UP Between 5˚ to 10˚
FAN Belt
 Section Exploded Views / Part Numbers
 Rotor Assembly
Stator Assembly
Flywheel Assembly
Bearing Carrier, Front
 Base Frame Drawing No D2357-A
 Door, Service Rear
Door, Service Front
Base Frame Weldment
Slide Latch Flush
 Enclosure Drawing No D2358-D
 Cover, Access Lift
Cover, Access Electrical
Gasket, Electrical Access
Decal, Battery +
 Views / Part
 Cover Plate, Scroll Weldment
 25 26
 Assembly, Potted Regulator
Assembly Marine Control Board
Rectifier, Battery Charging
Wire Assembly #
 Intake and Exhaust System Drawing No D2362-B
 Exhaust Gasket
Chamber Air Intake
Air Filter
Hose, Air Inlet
 Views / Part Numbers
 Fuel Pump Assembly
Boot, Battery Cable
Cable, Battery
Wire Assembly, Black #4 Ground
 Customer Controls Assembly Drawing No D2364-D
 Start / Stop Switch
Switch, Pushbutton Spst
Boot / Nut / Preheat Switch
Boot, Circuit Breaker
 Camshaft Assembly
Camshaft Gear
KEY
Gear
 2630
 Liter Diesel Cylinder Head Drawing No D2794
 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B
 Idler Gear Assembly
Spring
Thrust Washer
OIL Pump Cover
 Rocker ARM Assembly
Includes ALL Components Shown below
Intake Rocker ARM
Exhaust Rocker ARM
 Liter Diesel Injector Pump Drawing No -C
 Tank Return Model 04270 To Injection Pump To Fuel Pump
 27 25 19 18
 HOUSING, Timing Gear
 3114
 Liter Diesel Water Pump Drawing No
 Charts
 Engine Specifications
Generator Specifications
 ROTOR/STATOR Resistance Values
Type Quietpact Model
Page
 Data
 Data
 Electrical Data
 Schematic Drawing No C4945-A Model
C4945
 Electrical
C4946-A
 Sheet 2
 OF4996 REV. O