Diagnostic Repair Manual
Safety
Replacement Parts
Table of Contents
57-59
Electromagnetic Induction
Magnetism
Electromagnetic Fields
Simple AC Generator
More Sophisticated AC Generator
Generator Operating Diagram
Line Breakers 120 VAC only
Field Boost
Generator AC Connection System
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 Resistance
Measuring AC Frequency
Measuring Current
Electrical Units
Ohms LAW
Circuit CONDITION- OFF
Introduction
Operational Analysis
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 10 Check Brushes & Slip Rings
Test 11- Check Rotor Assembly
Tance Tests Procedure
Test 13- Check Load Voltage Frequency
Test 15 Check Battery Charge Output
Test 12 Check Main Circuit Breaker
Test 14- Check Load Watts & Amperage
Short to Ground
Test 16 Check Battery Charge Rectifier
Battery Charge Rectifier BCR is a full wave rectifier
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
Conditions Affecting Starter Motor Performance
Test 26- Test Starter Contactor
Test 27 Check Starter Motor
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 34- Test D1 Diode
Test 32- Test Preheat Contactor
Test 33- Test Glow Plugs
Test 36- Fuel Injector Pump
Test 35- Check Valve Adjustment
Remove the valve cover from engine Disconnect the battery
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 39- Check Circuit Board for Ground
Test 38 Check OIL Pressure Switch
Test 40- Test Water Temperature Switch
Components for Short to Ground
Test 43 Check Wire 15 for Short to Ground
If continuity is measure, replace the switch
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