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
 Excitation Circuit Components
Battery Charge Components
Brush Holder
General
 162
Adjust POT LED
Adjustment Procedure
Voltage Regulator
 Control Panel Component Identification
Control Panel Components
 Drying the Generator
Cleaning the Generator
Effects of Dirt and Moisture
Insulation Resistance Testers
 Cloth or Compressed AIR
Brushing and Vacuum Cleaning
Stator Insulation Resistance
Stator SHORT-TO-GROUND Tests
 Testing Rotor Insulation
Megohmmeter
 Measuring AC Voltage
Meters
VOM
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
 Charging a Battery
Effects of Temperature
Checking Battery State of Charge
Adding Water
 AMP Fuse
Preheat Switch
START/STOP Switch
Starter Contactor & Motor
 Fuel NOZZLES/INJECTORS
Engine Governor
Fuel Injection Pump
Glow Plugs
 Engine Protective Devices
LOW OIL Pressure Switch High Coolant Temperature Switch
Adapter LOW OIL Pressure Switch
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 6- Check Field Boost
Test 5- Wire Continuity
Re-connect Wire 11 and Wire 22 to the Voltage Regulator
Set a VOM to its Rx1 scale
 Test 7 Test Stator DPE Winding
Model QP75D
 159W
Test 8- Check Sensing Leads / Power Windings
Test 9- Check Brush Leads
184W
 Test 11- Check Rotor Assembly
Tance Tests Procedure
Test 10 Check Brushes & Slip Rings
 Test 13- Check Load Voltage Frequency
Test 15 Check Battery Charge Output
Test 12 Check Main Circuit Breaker
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 18 TRY Cranking the Engine
Test 19- Test PRE-HEAT Switch
Set a VOM to read battery voltage 12 VDC
Test 20- Check Fuel Pump
 Disconnect the connector from the wires of the fuel pump
Test 22- Check Battery & Cables
Test 23- Check Power Supply to Circuit Board
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
 Tools for Starter Performance Test
Checking the Pinion
Pinion
Measuring Current
 Test Bracket
Testing Starter Motor
Tachometer
Starter motor test bracket may be made as shown in Figure
 If Wire 18 checks GOOD, proceed to Problem 8 Section
Test 29 Check Wire 14 Power Supply
Test 30 Check Wire
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
 Down Test / Compression Test
If fuel is noted, proceed to next step in flowchart
Adjust the regulated pressure on the gauge to 80 psi
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
 Flywheel Assembly
Rotor Assembly
Stator Assembly
Bearing Carrier, Front
 Base Frame Drawing No D2357-A
 Base Frame Weldment
Door, Service Rear
Door, Service Front
Slide Latch Flush
 Enclosure Drawing No D2358-D
 Gasket, Electrical Access
Cover, Access Lift
Cover, Access Electrical
Decal, Battery +
 Views / Part
 Cover Plate, Scroll Weldment
 25 26
 Rectifier, Battery Charging
Assembly, Potted Regulator
Assembly Marine Control Board
Wire Assembly #
 Intake and Exhaust System Drawing No D2362-B
 Air Filter
Exhaust Gasket
Chamber Air Intake
Hose, Air Inlet
 Views / Part Numbers
 Cable, Battery
Fuel Pump Assembly
Boot, Battery Cable
Wire Assembly, Black #4 Ground
 Customer Controls Assembly Drawing No D2364-D
 Boot / Nut / Preheat Switch
Start / Stop Switch
Switch, Pushbutton Spst
Boot, Circuit Breaker
 KEY
Camshaft Assembly
Camshaft Gear
Gear
 2630
 Liter Diesel Cylinder Head Drawing No D2794
 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B
 Thrust Washer
Idler Gear Assembly
Spring
OIL Pump Cover
 Intake Rocker ARM
Rocker ARM Assembly
Includes ALL Components Shown below
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