Generac 75d Service
Generac 75d Service
Generac 75d Service
DIAGNOSTIC
REPAIR MANUAL
RECREATIONAL VEHICLE GENERATOR
MODEL 4270
SAFETY
Throughout this publication, "DANGER!" and "CAUTION!" blocks are used to alert the mechanic for special
instructions concerning a particular service or operation that might be hazardous if performed incorrectly or
carelessly. PAY CLOSE ATTENTION TO THEM.
DANGER! UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCTIONS WHICH, IF NOT COMPLIED WITH, COULD RESULT IN PERSONAL INJURY OR DEATH.
CAUTION! Under this heading will be found special instructions which, if not complied with, could
result in damage to equipment and/or property.
These "Safety Alerts" alone cannot eliminate the hazards that they signal. Strict compliance with these special Instructions plus "common sense" are major accident prevention measures.
REPLACEMENT PARTS
Components on Generac recreational vehicle generators are designed and manufactured to comply with
Recreational Vehicle Industry Association (RVIA) Rules and Regulations to minimize the risk of fire or explosion. The use of replacement parts that are not in compliance with such Rules and Regulations could result
in a fire or explosion hazard. When servicing this equipment, It is extremely important that all components be
properly installed and tightened. If parts are improperly installed or tightened, sparks could ignite fuel vapors
from fuel system leaks.
Table of Contents
SAFETY ............................ INSIDE FRONT COVER
SECTION 1:
GENERATOR FUNDAMENTALS ...................... 3-7
MAGNETISM ................................................................
ELECTROMAGNETIC FIELDS ....................................
ELECTROMAGNETIC INDUCTION ..............................
A SIMPLE AC GENERATOR ........................................
A MORE SOPHISTICATED AC GENERATOR ............
FIELD BOOST ..............................................................
GENERATOR AC CONNECTION SYSTEM ................
3
3
3
4
4
6
6
SECTION 2:
MAJOR GENERATOR COMPONENTS ............ 8-11
ROTOR ASSEMBLY ...................................................... 8
STATOR ASSEMBLY .................................................... 8
BRUSH HOLDER .......................................................... 9
BATTERY CHARGE COMPONENTS .......................... 9
EXCITATION CIRCUIT COMPONENTS ...................... 9
VOLTAGE REGULATOR ............................................ 10
CONTROL PANEL
COMPONENT IDENTIFICATION ................................ 11
SECTION 3:
INSULATION RESISTANCE TESTS ............ 12-14
EFFECTS OF DIRT AND MOISTURE ........................
INSULATION RESISTANCE TESTERS ......................
DRYING THE GENERATOR ......................................
CLEANING THE GENERATOR ..................................
STATOR INSULATION RESISTANCE ........................
TESTING ROTOR INSULATION ................................
THE MEGOHMMETER ..............................................
12
12
12
12
13
14
14
SECTION 4:
MEASURING ELECTRICITY ........................ 15-17
METERS ......................................................................
THE VOM ....................................................................
MEASURING AC VOLTAGE ......................................
MEASURING DC VOLTAGE ......................................
MEASURING AC FREQUENCY ................................
MEASURING CURRENT ............................................
MEASURING RESISTANCE ......................................
ELECTRICAL UNITS ..................................................
OHMS LAW ................................................................
15
15
15
15
16
16
16
17
17
SECTION 5:
ENGINE DC CONTROL SYSTEM ................ 18-28
INTRODUCTION ........................................................ 18
OPERATIONAL ANALYSIS .................................. 18-23
ENGINE CONTROLLER CIRCUIT BOARD ................ 24
BATTERY .................................................................... 24
14 AMP FUSE ............................................................ 26
PRE-HEAT SWITCH .................................................. 26
START-STOP SWITCH .............................................. 26
STARTER CONTACTOR & MOTOR ........................ 26
SECTION 6:
TROUBLESHOOTING FLOWCHARTS .................. 29-36
IF PROBLEM INVOLVES AC OUTPUT ...................... 29
PROBLEM 1 VOLTAGE & FREQUENCY ARE BOTH
HIGH OR LOW ............................................................ 29
PROBLEM 2 GENERATOR PRODUCES ZERO VOLTAGE OR
RESIDUAL VOLTAGE (5-12 VAC) ........................ 30-31
PROBLEM 3 NO BATTERY CHARGE OUTPUT .............................. 31
PROBLEM 4 EXCESSIVE VOLTAGE/FREQUENCY DROOP
WHEN LOAD IS APPLIED .......................................... 32
PROBLEM 5 PRIMING FUNCTION DOES NOT WORK .................. 32
PROBLEM 6 ENGINE WILL NOT CRANK ...................................... 33
PROBLEM 7 ENGINE CRANKS BUT WILL NOT START /
RUNS HARD .............................................................. 34
PROBLEM 8 ENGINE STARTS THEN SHUTS DOWN .................. 35
PROBLEM 9 14 AMP (F1) FUSE BLOWING .................................... 36
SECTION 7:
DIAGNOSTIC TESTS...................................... 37-57
INTRODUCTION ........................................................ 37
TEST 1 Check No-Load Voltage And Frequency ...................... 37
TEST 2 Check Engine Governor .......................................... 37-38
TEST 3 Test Excitation Circuit Breaker .................................... 38
TEST 4 Fixed Excitation Test/Rotor Amp Draw .................. 38-39
TEST 5 Wire Continuity ............................................................ 39
TEST 6 Check Field Boost .................................................. 39-40
TEST 7 Test Stator DPE Winding ........................................ 40-41
TEST 8 Check Sensing Leads/Power Windings ...................... 41
TEST 9 Check Brush Leads ................................................ 41-42
Page 1
Table of Contents
TEST 10 Check Brushes & Slip Rings ........................................ 42
TEST 11 Check Rotor Assembly ............................................ 42-43
TEST 12 Check Main Circuit Breaker .......................................... 43
TEST 13 Check Load Voltage & Frequency ................................ 43
TEST 14 Check Load Watts & Amperage .................................. 43
TEST 15 Check Battery Charge Output ................................ 43-44
TEST 16 Check Battery Charge Rectifier .................................... 44
TEST 17 Check Battery Charge Windings/
Battery Charge Resistor .......................................... 44-45
TEST 18 Try Cranking the Engine .............................................. 45
TEST 19 Test Pre-Heat Switch.................................................... 45
TEST 20 Check Fuel Pump .................................................... 45-46
TEST 21 Check 14 Amp Fuse .................................................... 46
TEST 22 Check Battery & Cables................................................ 46
TEST 23 Check Power Supply to Circuit Board .................... 46-47
TEST 24 Check Start-Stop Switch.......................................... 47-48
TEST 25 Check Power Supply to Wire 56 .................................. 48
TEST 26 Check Starter Contactor .............................................. 48
TEST 27 Check Starter Motor .............................................. 48-50
TEST 28 Check Fuel Supply........................................................ 51
TEST 29 Check Wire 14 Power Supply ...................................... 51
TEST 30 Check Wire 18 .............................................................. 51
TEST 31 Check Fuel Solenoid .............................................. 51-52
TEST 32 Test Pre-Heat Contactor .............................................. 52
TEST 33 Test Glow Plugs............................................................ 52
TEST 34 Test D1 Diode .............................................................. 52
Page 2
SECTION 8:
ASSEMBLY .................................................... 57-59
MAJOR DISASSEMBLY .............................................. 57
Enclosure/Panel Removal ...................................... 57
Stator Removal ........................................................ 57
Rotor Removal ........................................................ 57
Belt Tensioning ........................................................ 57
Engine Removal ...................................................... 57
Starter Removal ...................................................... 58
Fuel Injector Pump Removal .................................... 58
Radiator Removal .................................................... 58
Re-assembly ............................................................ 58
Belt Tensioning .................................................. 58-59
SECTION 9:
EXPLODED VIEWS / PART NUMBERS ...... 60- 87
SECTION 10:
SPECIFICATIONS & CHARTS ...................... 88-90
MAJOR FEATURES AND DIMENSIONS ....................
ENGINE SPECIFICATIONS ........................................
GENERATOR SPECIFICATIONS ..............................
ROTOR/STATOR RESISTANCE VALUES ................
TORQUE SPECIFICATIONS ......................................
88
89
89
90
90
SECTION 11:
ELECTRICAL DATA ............................................ 92
Section 1
GENERATOR FUNDAMENTALS
MAGNETISM
Magnetism can be used to produce electricity and
electricity can be used to produce magnetism.
Much about magnetism cannot be explained by our
present knowledge. However, there are certain patterns of behavior that are known. Application of these
behavior patterns has led to the development of generators, motors and numerous other devices that utilize magnetism to produce and use electrical energy.
See Figure 1-1. The space surrounding a magnet is
permeated by magnetic lines of force called flux.
These lines of force are concentrated at the magnet's
north and south poles. They are directed away from
the magnet at its north pole, travel in a loop and reenter the magnet at its south pole. The lines of force
form definite patterns which vary in intensity depending on the strength of the magnet. The lines of force
never cross one another. The area surrounding a
magnet in which its lines of force are effective is
called a magnetic field.
Like poles of a magnet repel each other, while unlike
poles attract each other.
NOTE: The right hand rule is based on the current flow theory which assumes that current
flows from positive to negative. This is opposite
the electron theory, which states that current
flows from negative to positive.
ELECTROMAGNETIC INDUCTION
ELECTROMAGNETIC FIELDS
All conductors through which an electric current is
flowing have a magnetic field surrounding them. This
field is always at right angles to the conductor. If a
compass is placed near the conductor, the compass
needle will move to a right angle with the conductor.
The following rules apply:
The greater the current flow through the conductor,
the stronger the magnetic field around the conductor.
The increase in the number of lines of force is
directly proportional to the increase in current flow
and the field is distributed along the full length of
the conductor.
The direction of the lines of force around a conductor can be determined by what is called the right
hand rule. To apply this rule, place your right hand
around the conductor with the thumb pointing in the
direction of current flow. The fingers will then be
pointing in the direction of the lines of force.
An electromotive force (EMF) or voltage can be produced in a conductor by moving the conductor so that
it cuts across the lines of force of a magnetic field.
Similarly, if the magnetic lines of force are moved so
that they cut across a conductor, an EMF (voltage)
will be produced in the conductor. This is the basic
principal of the revolving field generator.
Figure 1-3, below, illustrates a simple revolving field
generator. The permanent magnet (Rotor) is rotated
so that its lines of magnetic force cut across a coil of
wires called a Stator. A voltage is then induced into
the Stator windings. If the Stator circuit is completed
by connecting a load (such as a light bulb), current
will flow in the circuit and the bulb will illuminate.
Page 3
Section 1
GENERATOR FUNDAMENTALS
A SIMPLE AC GENERATOR
Figure 1-4 shows a very simple AC Generator. The
generator consists of a rotating magnetic field called
a ROTOR and a stationary coil of wire called a STATOR. The ROTOR is a permanent magnet which consists of a SOUTH magnetic pole and a NORTH magnetic pole.
As the MOTOR turns, its magnetic field cuts across
the stationary STATOR. A voltage is induced into the
STATOR windings. When the magnet's NORTH pole
passes the STATOR, current flows in one direction.
Current flows in the opposite direction when the magnet's SOUTH pole passes the STATOR. This constant reversal of current flow results in an alternating
current (AC) waveform that can be diagrammed as
shown in Figure 1-5.
The ROTOR may be a 2-pole type having a single
NORTH and a single SOUTH magnetic pole. Some
ROTORS are 4-pole type with two SOUTH and two
NORTH magnetic poles. The following apply:
1. The 2-pole ROTOR must be turned at 3600 rpm to produce an
AC frequency of 60-Hertz, or at 3000 rpm to deliver an AC frequency of 50-Hertz.
360
180
(-)
ONE CYCLE
DC CURRENT
STATOR
VOLTAGE
(+)
AC OUTPUT
2. The 4-pole ROTOR must operate at 1800 rpm to deliver a 60Hertz AC frequency or at 1500 rpm to deliver a 50-Hertz AC
frequency.
CURRENT
120 V
STATOR
STATOR
240 V
120 V
BRUSHES
SLIP
RINGS
ROTOR
MAGNETIC FIELD
Page 4
Section 1
GENERATOR FUNDAMENTALS
c.
b.
c.
Page 5
Section 1
GENERATOR FUNDAMENTALS
FIELD BOOST
When the engine is cranked during startup, the
engine control circuit board Terminals 9, 10, and 11
(Wire 14) are energized with 12 VDC. Connected to a
Wire 14 is a resistor (R2) and a diode (D2). Battery
current flows through the 20 ohm 12-watt resistor and
the field boost diode D2, the voltage is reduced to 3-5
VDC. After passing through R2 and D2 it becomes
Wire 4 and current travels to the Rotor via brushes
and slip rings. This is called Field Boost current.
The effect is to flash the field every time the engine
is cranked. Field boost current helps ensure that sufficient pickup voltage is available on every startup to
turn the Voltage Regulator on and build AC output
voltage.
NOTE: Loss of the Field Boost function may or
may not result in loss of AC power winding output. If Rotor residual magnetism alone is sufficient to turn the Regulator on, loss of Field Boost
may go unnoticed. However, if residual magnetism alone is not enough to turn the Regulator on,
loss of the Field Boost function will result in loss
of AC power winding output to the load. The AC
output voltage will then drop to a value commensurate with the Rotor's residual magnetism (about
7-12 VAC).
Page 6
Circuit Breaker 1
Circuit Breaker 2
QuietPact 75D
35A
35A
GENERATOR CONVERSION TO
120 VAC ONLY DUAL CIRCUITS
NOTE: Conversion of a QUIETPACT generator
from "120/240 VAC dual voltage" to "120 VAC
only - dual circuits" (or vice-versa) requires
rerouting wires within the unit enclosure. It is recommended that this conversion be performed by
a Generac Authorized Service Dealer.
Figure 1-9 shows the stator power winding connections for 120 VAC only - dual circuits. Two stator
power windings are used, with each winding capable
of supplying half of the unit's rated wattage/amperage
capacity. The circuit from each winding is protected
against overload by a line breaker (CB1 and CB1A).
Line breakers CB1 and CB1A have a trip rating of 35
amps.
To convert from "120/240 VAC dual voltage" to "120
VAC only - dual circuits", disconnect battery power
from the generator and reverse stator lead Wires 33
and 44 as follows:
NOTE: It is necessary to feed stator lead Wires 33
and 44 through grommets on the electrical enclosure and engine control box in order to perform
the rerouting outlined below. The front and top
unit enclosure panels, as well as the user control
panel, must be removed to perform this. After rerouting, wires should be properly tied down to
prevent chafing or contact with moving internal
components
1. Remove stator lead Wire 33, as shown in Figure 1-8, from the
ground stud adjacent to the four-position terminal block.
Section 1
GENERATOR FUNDAMENTALS
Reroute stator lead 44 from the line side terminal of CB1
(renamed as CB1A in Figure 1-9) to the ground stud location
previously occupied by stator lead Wire 33.
2. Move smaller gauge (#18 AWG) Wire labeled #44 (not shown),
from the top of CB1A to the top of CB1. Renumber this Wire 11.
3. Reroute stator lead Wire 33, removed in step 1, to the line side
terminal on CB1A.
4. Renumber ground Wire 33, located between the four-position
terminal block and ground in Figure 1-8, as ground Wire 44, as
shown in Figure 1-9.
5. Renumber Wire 44A from Figure 1-8 as Wire 33A in Figure 1-9.
6. Connect a 12 AWG jumper wire between line breakers CB1
and CB1A, as shown in Figure 1-9.
7. Remove the "tie bar" between the two-line breaker switch handles.
When connecting vehicle load leads, the following
rules apply:
Connect 120 VAC, single-phase, 60-Hertz, AC
electrical loads, requiring up to the trip rating of circuit breaker CB1, across AC output leads T1 (red)
and T2 (white).
Connect 120 VAC, single-phase, 60-Hertz, AC
electrical loads, requiring up to the trip rating of circuit breaker CB1A, across AC output leads T3
(black) and T2 (white).
Try to keep the load balanced between the two circuit breakers and the stator windings.
The neutral line (T2, white) on all units is a grounded neutral.
Page 7
Section 2
MAJOR GENERATOR COMPONENTS
ENGINE
BRUSH HOLDER
FLYWHEEL/PULLEY
STATOR
BEARING
ROTOR
BEARING
BEARING
CARRIER
TENSIONER
BEARING CARRIER
PULLEY
BELT
ROTOR ASSEMBLY
STATOR ASSEMBLY
Page 8
2. Stator Power winding sensing leads (11 and 22). These leads
deliver an actual voltage signal to the electronic Voltage
Regulator.
Section 2
MAJOR GENERATOR COMPONENTS
3. Two excitation winding output leads (No. 2 and 6). These leads
deliver unregulated excitation current to the voltage regulator.
TO ENGINE
CONTROLLER
CIRCUIT BOARD
4. Three (3) battery charge output leads (No. 55, 66 and 77).
BCR
66
TO BATTERY
15
66
77
11
11
55
22
R1
0N
22
33
44
55
66
77
Leads 2 & 6 =Stator Excitation Winding
Leads 11 & 22 = Voltage Sensing Leads
Leads 11 & 22, 33 & 44 = AC Power Windings
Leads 55, 66, 77 = Battery Charge Windings
BRUSH HOLDER
The brush holder is retained in the rear bearing carrier by two M5 screws. It retains two brushes, which
contact the Rotor slip rings and allow current flow
from stationary parts to the revolving Rotor. The positive (+) brush is located nearest the Rotor bearing.
POWER WINDING
22S
11S
ELECTRONIC
VOLTAGE
REGULATOR
0K
2A
CB2
4
2
6
DPE WINDING
0F
4
FIELD
BRUSHES
Page 9
Section 2
MAJOR GENERATOR COMPONENTS
11
22
4
1
6
162
VOLTAGE
ADJUST POT
162
LED
Page 10
ADJUSTMENT PROCEDURE:
With the frequency set at 62.5-Hertz and no load on
the generator, slowly turn the voltage adjust pot on
the voltage regulator until 124 VAC is measured. If
voltage is not adjustable, proceed to Section 6 Troubleshooting.
NOTE: If, for any reason, sensing voltage to the
regulator is lost, the regulator will shut down and
excitation output to the Rotor will be lost. The AC
output voltage will then drop to a value that is
equal to Rotor residual magnetism (about 7-12
VAC). Without this automatic shutdown feature,
loss of sensing (actual) voltage to the regulator
would result in a full field or full excitation
condition and an extremely high AC output voltage.
NOTE: Adjustment of the regulator's VOLTAGE
ADJUST potentiometer must be done only when
the unit is running at its correct governed no-load
speed. Speed is correct when the unit's no-load
AC output frequency is about 62.5-Hertz. At the
stated frequency, AC output voltage should be
about 125 volts.
Section 2
MAJOR GENERATOR COMPONENTS
Section 3
INSULATION RESISTANCE TESTS
Page 12
Section 3
INSULATION RESISTANCE TESTS
DANGER!: DO NOT ATTEMPT TO WORK
WITH SOLVENTS IN ANY ENCLOSED AREA.
PROVIDE ADEQUATE VENTILATION WHEN
WORKING WITH SOLVENTS. WITHOUT ADEQUATE VENTILATION, FIRE, EXPLOSION OR
HEALTH HAZARDS MAY EXIST . WEAR EYE
PROTECTION. WEAR RUBBER GLOVES TO
PROTECT THE HANDS.
CLOTH OR COMPRESSED AIR:
For small parts or when dry dirt is to be removed, a
dry cloth may be satisfactory. Wipe the parts clean,
then use low pressure air at 30 psi (206 Kpa) to blow
dust away.
BRUSHING AND VACUUM CLEANING:
Brushing with a soft bristle brush followed by vacuum
cleaning is a good method of removing dust and dirt.
Use the soft brush to loosen the dirt, then remove it
with the vacuum.
d.
e.
f.
g.
2
6
11
11
22
22
33
44
55
66
77
Leads 2 & 6 =Stator Excitation Winding
Leads 11 & 22 = Voltage Sensing Leads
Leads 11 & 22, 33 & 44 = AC Power Windings
Leads 55, 66, 77 = Battery Charge Windings
Page 13
Section 3
INSULATION RESISTANCE TESTS
a.
b.
c.
d.
POSITIVE (+)
TEST LEAD
Page 14
THE MEGOHMMETER
GENERAL:
A megohmmeter, often called a megger, consists of
a meter calibrated in megohms and a power supply.
Use a power supply of 1500 volts when testing
Stators; or 1000 volts when testing the Rotor. DO
NOT APPLY VOLTAGE LONGER THAN ONE (1)
SECOND.
TESTING STATOR INSULATION:
All parts that might be damaged by the high megger
voltages must be disconnected before testing. Isolate
all Stator leads (Figure 3-2) and connect all of the
Stator leads together. FOLLOW THE MEGGER
MANUFACTURER'S INSTRUCTIONS CAREFULLY.
Use a megger power setting of 1500 volts. Connect
one megger test lead to the junction of all Stator
leads, the other test lead to frame ground on the
Stator can. Read the number of megohms on the
meter.
MINIMUM INSULATION
RESISTANCE
(in Megohms)
+1
Section 4
MEASURING ELECTRICITY
METERS
MEASURING AC VOLTAGE
THE VOM
A meter that allows both voltage and resistance to be
read is the volt-ohm-milliammeter or VOM.
Some VOM's are of the analog type (not shown).
These meters display the value being measured by
physically deflecting a needle across a graduated
scale. The scale used must be interpreted by the
user.
Digital VOM's (Figure 4-1) are also available and
are generally very accurate. Digital meters display the
measured values directly by converting the values to
numbers.
NOTE: Standard AC voltmeters react to the AVERAGE value of alternating current. When working
with AC, the effective value is used. For that reason a different scale is used on an AC voltmeter.
The scale is marked with the effective or rms
value even though the meter actually reacts to the
average value. This is why the AC voltmeter will
give an incorrect reading if used to measure
direct current (DC).
MEASURING DC VOLTAGE
A DC voltmeter or a VOM can be used to measure
DC voltages. Always observe the following rules:
1. Always observe correct DC polarity.
a.
b.
b.
Page 15
Section 4
MEASURING ELECTRICITY
MEASURING AC FREQUENCY
The generator's AC output frequency is proportional
to Rotor speed. Generators equipped with a 2-pole
Rotor must operate at 3600 rpm to supply a frequency of 60-Hertz.
Correct engine and Rotor speed is maintained by an
engine speed governor. For models rated 60-Hertz,
the governor is generally set to maintain a no-load
frequency of about 62-Hertz with a corresponding
output voltage of about 125 VAC line-to-neutral.
Engine speed and frequency at no-load are set slightly high to prevent excessive rpm and frequency droop
under heavy electrical loading.
MEASURING CURRENT
To read the current flow, in AMPERES, a clamp-on
ammeter can be used. This type of meter indicates
current flow through a conductor by measuring the
strength of the magnetic field around that conductor.
The meter consists essentially of a current transformer with a split core and a rectifier type instrument
connected to the secondary. The primary of the current transformer is the conductor through which the
current to be measured flows. The split core allows
the instrument to be clamped around the conductor
without disconnecting it.
Current flowing through a conductor may be measured safely and easily. A line-splitter can be used to
measure current in a cord without separating the conductors.
Page 16
MEASURING RESISTANCE
The volt-ohm-milliammeter may be used to measure
the resistance in a circuit. Resistance values can be
very valuable when testing coils or windings, such as
the Stator and Rotor windings.
When testing Stator windings, keep in mind that the
resistance of these windings is very low. Some
meters are not capable of reading such a low resistance and will simply read continuity.
If proper procedures are used, the following conditions can be detected using a VOM:
A short-to-ground condition in any Stator or Rotor
winding.
Shorting together of any two parallel Stator windings.
Shorting together of any two isolated Stator windings.
An open condition in any Stator or Rotor winding.
Component testing may require a specific resistance
value or a test for infinity or continuity. Infinity is an
OPEN condition between two electrical points, which
would read as no resistance on a VOM. Continuity is
a closed condition between two electrical points,
which would be indicated as very low resistance or
ZERO on a VOM.
Section 4
MEASURING ELECTRICITY
ELECTRICAL UNITS
AMPERE:
The rate of electron flow in a circuit is represented by
the AMPERE. The ampere is the number of electrons
flowing past a given point at a given time. One
AMPERE is equal to just slightly more than six thousand million billion electrons per second.
With alternating current (AC), the electrons flow first
in one direction, then reverse and move in the opposite direction. They will repeat this cycle at regular
intervals. A wave diagram, called a sine wave
shows that current goes from zero to maximum positive value, then reverses and goes from zero to maximum negative value. Two reversals of current flow is
called a cycle. The number of cycles per second is
called frequency and is usually stated in Hertz.
VOLT:
The VOLT is the unit used to measure electrical
PRESSURE, or the difference in electrical potential
that causes electrons to flow. Very few electrons will
flow when voltage is weak. More electrons will flow as
voltage becomes stronger. VOLTAGE is considered
to be a state of unbalance and current flow as an
attempt to regain balance. One volt is the amount of
EMF that will cause a current of one ampere to flow
through one ohm of resistance.
OHM'S LAW
A definite and exact relationship exists between
VOLTS, OHMS and AMPERES. The value of one can
be calculated when the value of the other two are
known. Ohm's Law states that in any circuit the current
will increase when voltage increases but resistance
remains the same, and current will decrease when
resistance increases and voltage remains the same.
VOLTS
(E)
AMPS
(I)
Conductor of a
Circuit
OHM:
The OHM is the unit of RESISTANCE. In every circuit
there is a natural resistance or opposition to the flow
of electrons. When an EMF is applied to a complete
circuit, the electrons are forced to flow in a single
direction rather than their free or orbiting pattern. The
resistance of a conductor depends on (a) its physical
makeup, (b) its cross-sectional area, (c) its length,
and (d) its temperature. As the conductor's temperature increases, its resistance increases in direct proportion. One (1) ohm of resistance allows one (1)
ampere of current to flow when one (1) volt of electromotive force (EMF) is applied.
OHMS
(R)
+
AMPERE - Unit measuring rate of
current flow (number of electrons
past a given point)
Figure 4-5.
If AMPERES is unknown while VOLTS and OHMS
are known, use the following formula:
AMPERES = VOLTS
OHMS
If VOLTS is unknown while AMPERES and OHMS
are known, use the following formula:
VOLTS = AMPERES x OHMS
If OHMS is unknown but VOLTS and AMPERES are
known, use the following:
VOLTS
OHMS = AMPERES
Page 17
Section 5
ENGINE DC CONTROL SYSTEM
INTRODUCTION
The engine DC control system includes all components necessary for the operation of the engine.
Operation includes off, preheat, cranking/starting,
running, shutdown, and fault shutdown. The system
is shown schematically.
OPERATIONAL ANALYSIS
CIRCUIT CONDITION- OFF:
Battery voltage is available to the engine controller
circuit board from the unit BATTERY and via (a) the
RED battery cable, Wire 13, a 14 amp FUSE (F1),
Wire 15 and engine controller Terminal 1. However,
circuit board action is holding the circuit open and no
action can occur.
Battery voltage is available to the contacts of a
STARTER CONTACTOR (SC), but the contacts are
open.
Battery voltage is available to the contacts of a PREHEAT CONTACTOR (PHC), but the contacts are
open.
Battery voltage is available to the PREHEAT
SWITCH (SW).
The switch is open and the circuit is incomplete.
Battery voltage is also available to the remote connection for a remote preheat switch.
Battery voltage is available to the BATTERY
CHARGE RECTIFIER (BCR). This is used as a
return path for Battery Charge Winding current.
Page 18
Section 5
ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- PRE-HEAT:
When the PRE-HEAT SWITCH (SW) or the
REMOTE PANEL PRE-HEAT SWITCH is closed by
the operator, battery voltage is delivered across the
closed switch contacts to the PRE-HEAT CONTACTOR (PHC) via Wire 150. The PRE-HEAT CONTACTOR (PHC) is now energized. The normally open
(PHC) contacts close, battery voltage is now available to Wire 157.
The GLOW PLUGS (GP) are energized via Wire 157.
Wire 157 is also connected to a DIODE (D1), current
is allowed to pass through (D1) and Wire 14 will now
have battery voltage applied to it " Engine Controller
Terminals 9, 10 , and 11 are connected".
The FUEL PUMP (FP), FUEL SOLENOID (FS), and
HOURMETER (HM) will be energized via Wire 14.
Wire 14 is also connected to RESISTOR (R2) and
DIODE (D2). After passing through R2 and D2
reduced voltage is applied to Wire 4.
Page 19
Section 5
ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- CRANKING:
When the START-STOP-SWITCH (SW1) or REMOTE
PANEL START-STOP-SWITCH is held at "START"
position, Wire 17 from the Engine Control circuit board
is connected to Ground. Engine control circuit board
action will then deliver battery voltage to a STARTER
CONTACTOR (SC) via Terminal 7 Wire 56.
The STARTER CONTACTOR (SC) energizes and its
contacts close, battery output is delivered to the
STARTER MOTOR (SM) via Wire 16.The STARTER
MOTOR energizes and the engine cranks.
Also, while cranking, engine control circuit board
action energizes Terminals 9, 10, and 11 which delivers battery voltage to the Wire 14 circuit. This energizes the FUEL PUMP (FP), FUEL SOLENOID (FS),
HOURMETER (HM), and optional light or hourmeter
in remote panel.
Wire 14 is also connected to RESISTOR (R2) and
DIODE (D2). After passing through R2 and D2
reduced voltage is applied to Wire 4. The reduced
voltage, approximately 3-5VDC, is sent to the
ROTOR via The BRUSHES and SLIP RINGS. This
voltage is used for Field Boost.
Also while cranking, engine control circuit board
action energizes Terminal 12 which delivers battery
voltage to Wire 85. "Refer to Circuit Condition-Fault
Shutdown for operation".
Page 20
Section 5
ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION-RUNNING:
With the FUEL PUMP (FP) and FUEL SOLENOID
(FS) operating the engine should start. The STARTSTOP SWITCH (SW1) is then released. Engine control circuit board action terminates DC output to the
STARTER CONTACTOR (SC), which then de-energizes the (SC) to end cranking.
While running, engine control circuit board action
keeps Terminals 9, 10, and 11 energized which delivers battery voltage to the Wire 14 circuit. This energizes the FUEL PUMP (FP), FUEL SOLENOID (FS),
HOURMETER (HM), and optional light or hourmeter
in remote panel. This will maintain engine operation.
While running, engine control circuit board action
keeps Terminal 12 (Wire 85) energized with battery
voltage. Connected in parallel to Wire 85 are the
LOW OIL PRESSURE SWITCH (LOS) and HIGH
WATER TEMP SWITCH (HWT). The (LOS) has normally closed contacts. After start-up, engine oil pressure will open the contacts. The HWT has normally
open contacts. High coolant temperature will close
the contacts. "Refer to Circuit Condition-Fault
Shutdown for operation".
A voltage is induced into the Stator's POWER WINDING. This voltage is delivered to the Engine control
circuit board Terminals 5 & 6 (via Wires 22 & 44).
The engine control circuit board uses this frequency
signal to determine engine speed for overspeed
sensing and starter disengage.
Page 21
Section 5
ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- SHUTDOWN:
Setting the START-STOP SWITCH (SW1) or the
REMOTE PANEL START-STOP SWITCH to its
"STOP" position, connects the Wire 18 circuit to
ground. ENGINE CONTROL circuit board action deenergizes DC output to Terminal 9,10, & 11 (Wire
14). The FUEL PUMP (FP), FUEL SOLENOID (FS)
and HOURMETER (HM) are de-energized by the
loss of DC to Wire 14. Fuel flow terminates and the
engine shuts down.
Page 22
Section 5
ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- FAULT SHUTDOWNS:
The engine has mounted to it a HIGH WATER TEMPERATURE SWITCH (HWT) and a LOW OIL PRESSURE SWITCH (LOS). While running, ENGINE
CONTROL circuit board action keeps Terminal 12
Wire 85 energized with battery voltage. Connected in
parallel to (Wire 85) are the LOW OIL PRESSURE
SWITCH (LOS) and HIGH WATER TEMP SWITCH
(HWT). The (LOS) has normally closed contacts.
After start-up, engine oil pressure will open the contacts. The HWT has normally open contacts. High
coolant temperature will close the contacts.
Should engine water temperature exceed a preset
value, the switch contacts will close. Wire 85 from the
circuit board will connect to ground. Circuit board
action will then initiate a shutdown.
Should engine oil pressure drop below a safe pre-set
value, the switch contacts will close.
On contact closure, Wire 85 will be connected to
ground and circuit board action will initiate an engine
shutdown.
The circuit board has a time delay built into it for the
Wire 85 fault shutdowns. At STARTUP ONLY the circuit board will wait approximately six (6) seconds
before looking at the Wire 85 fault shutdowns. Once
running after the six (6) second time delay, grounding
Wire 85 through either switch will cause an immediate shutdown.
The ENGINE CONTROL circuit board also has overspeed protection. The circuit board senses the AC
output from the stators POWER winding at Terminals
5 & 6 via Wires 22 & 44. This AC voltage and frequency signal is used indirectly to monitor engine
RPM. If the frequency should increase above a preset "adjustable" limit, the ENGINE CONTROL circuit
board will cause an immediate shutdown.
Page 23
Section 5
ENGINE DC CONTROL SYSTEM
WIRE
15
FUNCTION
4. Connect all wires to proper circuit board terminals. Follow electrical schematic if needed.
Common Ground
17
6. Turn the overspeed shutdown potentiometer slowly counterclockwise until it stops. DO NOT FORCE.
18
44
22
56
__
Not Used
14
10. Hold the throttle at 64 hertz and SLOWLY turn the overspeed
shutdown potentiometer clockwise until engine shutdown
occurs.
10
14
11
14
12
85
LED FUNCTIONS:
Green LED will be illuminated when Wire 14 is energized during cranking and running.
Red LED will be illuminated when Wire 56 is energized during cranking only.
Page 24
BATTERY
RECOMMENDED BATTERY:
When anticipated ambient temperatures will be consistently above 32 F. (0 C.), use a 12 VDC automotive type storage battery rated 70 amp-hours and
capable of delivering at least 360 cold cranking
amperes.
The QUIETPACT 75D generator is rated at about 160
DC Amps of cranking current to operate the starter
and glow plugs.
BATTERY CABLES:
Use of battery cables that are too long or too small in
diameter will result in excessive voltage drop. For
best cold weather starting, voltage drop between the
Section 5
ENGINE DC CONTROL SYSTEM
TERMINALS:
10
11
12
OVERSPEED
SHUTDOWN
POTENTIOMETER
GREEN LED
RED LED
TERMINALS:
EFFECTS OF TEMPERATURE:
Battery efficiency is greatly reduced by a decreased
electrolyte temperature. Such low temperatures have
a decided numbing effect on the electrochemical
action. Under high discharge rates (such as cranking), battery voltage will drop to much lower values in
cold temperatures than in warmer temperatures. The
freezing point of battery electrolyte fluid is affected by
the state of charge of the electrolyte as indicated
below:
SPECIFIC GRAVITY
1.220
1.200
1.160
FREEZING POINT
-35 F. (-37 C.)
--20 F. (-29 C.)
0 F. (-18 C.)
ADDING WATER:
Water is lost from a battery as a result of charging
and discharging and must be replaced. If the water is
not replaced and the plates become exposed, they
may become permanently sulfated. In addition, the
plates cannot take full part in the battery action unless
they are completely immersed in electrolyte. Add only
PERCENTAGE OF CHARGE
100%
75%
50%
25%
CHARGING A BATTERY:
Use an automotive type battery charger to recharge a
battery. Battery fluid is an extremely corrosive, sulfuric acid solution that can cause severe burns. For that
reason, the following precautions must be observed:
The area in which the battery is being charged must
be well ventilated. When charging a battery, an
explosive gas mixture forms in each cell.
Do not smoke or break a live circuit near the top of
the battery. Sparking could cause an explosion.
Avoid spillage of battery fluid. If spillage occurs,
flush the affected area with clear water immediately.
Wear eye protection when handling a battery.
Page 25
Section 5
ENGINE DC CONTROL SYSTEM
14 AMP FUSE
This panel-mounted Fuse protects the DC control circuit against overload and possible damage. If the
Fuse has melted open due to an overload, neither the
priming function nor the cranking function will be
available.
Figure5-4
WIRE 0:
Connects the switch to ground.
PREHEAT SWITCH
The diesel engine is equipped with glow plugs, one
for each cylinder. When the preheat switch is
pressed, voltage will go through the switch to the preheat contactor. The preheat contactor (normally
open) now closes, allowing battery voltage to go to
the glow plugs via Wire 157. Power from Wire 157
goes through a diode and changes to Wire 14. This
Wire 14 goes to the circuit board powering the fuel
pump, fuel solenoid, hourmeter, and field boost
through another diode and resistor. The glow plugs
now heat the engine combustion chamber, and the
injector pump is primed with fuel for starting.
17
(START)
SW1
18
18
(STOP)
0
17
A. Schematic
B. Pictorial
150
15
150
13 TO FUSE
150
B. Schematic
OUTER POSTS
15
SMALL
LUGS
13
A. Pictorial
TO BATTERY
TO GROUND
56 TO BOARD
START/STOP SWITCH
The start/stop switch allows the operator to control
cranking, startup, and shutdown. The following wires
connect to the start/stop switch:
Page 26
16
TO STARTER
Section 5
ENGINE DC CONTROL SYSTEM
The positive (+) battery cable (13) attaches to one of
the outer posts of the contactor along with Wire 13 for
the DC supply to the fuse (F1). The starter cable (16)
attaches to the remaining outer post. Attached to the
small 2 lugs are Wires 56 and 0. When the start/stop
switch is set to start, the circuit board delivers battery
voltage to the contactor coil via Wire 56. The contactor energizes and its contacts close. Battery voltage
is then delivered from the positive battery cable,
across contacts and to the starter motor via Wire 16.
FUEL NOZZLES/INJECTORS
Fuel supplied by the injector pump is delivered to the
nozzle holder and to the nozzle body. When fuel
pressure is sufficient to compress the spring, fuel is
supplied from the nozzle and into the combustion
chamber. Due to the high pressure of fuel being
ejected from the nozzle, there is no safe test. If faulty
fuel is suspected and a clogged injector pump was
diagnosed, the replacement of the injector nozzles
would be needed.
ENGINE GOVERNOR
A mechanical, all-speed governor is used on the
diesel engine. It is housed in the gear case. A flyweight movement is transmitted to the injection pump
control rack by way of the slider, control lever and
link. A spring is attached to the arm and the tension
lever. The spring regulates flyweight movement. By
changing the set angle of the governor lever, tension
on the tension lever spring is changed. In this manner, engine speed can be regulated by the governor
lever.
The generators A/C output frequency is directly proportional to engine speed. Low governor speed will
result in a reduced A/C frequency and voltage, and
high governor speed will produce an increased frequency and voltage.
INJECTOR
CAP
INSERT
GASKET
CONTROL RACK
SHIM
VALVE
CLOSED
VALVE
OPEN
FULLY
OPEN
INJECTOR PUMP
GLOW PLUGS
The glow plug consists of a thin coiled heat-wire that
is encased in sintered magnesium oxide powder and
enclosed by a stainless steel sheath. One end of the
wire is welded to the sheath and the other end is
welded to the center electrode. When voltage is
applied to the center electrode, it heats the heat-wire,
which in turn, heats the combustion chamber.
Glow plugs are connected in parallel. For that reason, if one plug fails open, the other plugs will continue to operate. However, loss of one plug will
increase the possibility of the heat-wire melting open
in the remaining plugs.
Page 27
Section 5
ENGINE DC CONTROL SYSTEM
ASBESTOS
BODY
NUT
HEAT-WIRE
MAGNESIUM
OXIDE
POWDER
INSULATING
BUSHING
CENTER
ELECTRODE
Page 28
OVERSPEED PROTECTION
Generator A/C frequency signals are delivered to
Terminals 5 and 6 of the engine control circuit board
via wires 22 and 44. Should engine/generator speed
exceed 69 to 71 Hertz for longer than 4 seconds, the
circuit board will cause an engine shutdown.
Section 6
TROUBLESHOOTING FLOWCHARTS
INTRODUCTION
The Flow Charts in this section can be used in conjunction with the Diagnostic Tests of Section 7.
Numbered tests in the Flow Charts correspond to
identically numbered tests of Section 7.
Page 29
Section 6
TROUBLESHOOTING FLOWCHARTS
Page 30
Section 6
TROUBLESHOOTING FLOWCHARTS
E
TEST 11 CHECK ROTOR
ASSEMBLY
REPLACE FUSES
- THEN RETEST
F
BAD
REPAIR
OR
REPLACE
INSULATION
RESISTANCE
TEST PAGE 14
GOOD
TEST 8 - CHECK
SENSING LEADS /
POWER WINDINGS
GOOD
BAD
EITHER OR
BOTH BAD
INSULATION
RESISTANCE
TEST PAGE 13
REPAIR
OR
REPLACE
BAD
BAD
GOOD
FINISHED
GOOD
TEST 16 CHECK
BATTERY
CHARGE
RECTIFIER
GOOD
BAD
BAD
REPLACE
REPAIR
OR REPLACE
INSULATION
RESISTANCE
TEST PAGE 13
BAD
REPAIR
OR
REPLACE
Page 31
Section 6
TROUBLESHOOTING FLOWCHARTS
Page 32
Section 6
TROUBLESHOOTING FLOWCHARTS
Page 33
Section 6
TROUBLESHOOTING FLOWCHARTS
Page 34
Section 6
TROUBLESHOOTING FLOWCHARTS
Page 35
Section 6
TROUBLESHOOTING FLOWCHARTS
Page 36
Section 7
DIAGNOSTIC TESTS
INTRODUCTION
The Diagnostic Tests in this chapter may be performed in conjunction with the Flow Charts of
Section 6. Test numbers in this chapter correspond to
the numbered tests in the Flow Charts.
Tests 1 through 17 are procedures involving problems
with the generator's AC output voltage and frequency
(Problems 1 through 4 in the Flow Charts).
Tests 18 through 42 are procedures involving problems with engine operation (Problems 5 through 9 in
the Troubleshooting Flow Charts).
Review and become familiar with Section 4,
Measuring Electricity.
NOTE: Test procedures in this Manual are not necessarily the only acceptable methods for diagnosing the condition of components and circuits. All
possible methods that might be used for system
diagnosis have not been evaluated. If any diagnostic method other than the method presented in this
Manual is utilized, ensure that neither personnel
safety nor the product's safety will be endangered
by the procedure or method utilized.
4. If the no-load voltage and frequency are within the stated limits,
go to Test 13.
NOTE: The term low voltage refers to any voltage reading that is lower than the unit's rated voltage. The term residual voltage refers to the output voltage supplied as a result of Rotor residual
magnetism (approximately 5-12 VAC).
DISCUSSION:
Rotor operating speed and A/C output frequency is
proportional. The generator will deliver a frequency of
60 HERTZ at 1950 RPM or 62 HERTZ at 2015 RPM.
The voltage regulator should be adjusted to deliver
120 VAC (line-to-neutral) at a frequency of 60 HERTZ
or 124 VAC (line-to-neutral) at 62 HERTZ. It is apparent that if governor speed is high or low, A/C frequency and voltage will be correspondingly high or low.
Governor speed at no-load is usually set slightly
above the rated speed of 60HERTZ (to 62.8 HERTZ)
to prevent excessive RPM, frequency, and voltage
droop under heavy electrical loading.
DISCUSSION:
The first step in analyzing any problem with the AC
generator is to determine the unit's AC output voltage
and frequency.
PROCEDURE:
1. Set a volt-ohm-milliammeter (VOM) to read AC voltage.
Connect the meter test leads across customer connection
leads T1 (Red) and T2 (White).
2. Disconnect or turn OFF all electrical loads. Initial checks and
adjustments are accomplished at no-load.
3. Start the engine, let it stabilize and warm up.
4. Read the AC voltage.
5. Connect an AC frequency meter across AC output leads T1
(Red) and T2 (White) on the customer connection. Repeat the
above procedure.
RESULTS:
For units rated 60-Hertz, no-load voltage and frequency should be approximately 122-126 VAC and 61-63
Hertz respectively.
1. If AC voltage and frequency are BOTH correspondingly high or
low, go to Test 2.
2. If AC frequency is good but low or residual voltage is indicated,
go to Test 3.
Page 37
Section 7
DIAGNOSTIC TESTS
line voltage should read between 242-252 VAC. If voltage and
frequency are good, no adjustment is needed. If voltage and
frequency are low or high, proceed to next step.
4. Turn the governor adjusting screws to obtain a no-load frequency as close as possible to 62-63 HERTZ. With no-load frequency set, apply an electrical load as close as possible to the unit's
rated load. Frequency with load applied should not fall below
58 HERTZ. If units frequency continues to drop below 58
HERTZ while under load, check for an overload condition.
2A
RESULTS:
1. If the meter did NOT read continuity, replace the excitation
(DPE) circuit breaker (CB2), and go to Test 4.
2. If continuity was indicated, go to Test 4.
WIRE NO. 4
TO ROTOR
AND TO ECB
0 6
162
VOLTAGE
REGULATOR
TERMINALS
CB3
PROCEDURE:
1. Disconnect Wire 4 from the Voltage Regulator (VR). (Third terminal from the top of VR).
2. Connect a jumper wire to Wire 4 and to the 12 volt fused battery
positive supply Wire 15 (Wire 15 located at fuse (F1) holder).
3. Connect the meter test leads across the two circuit breaker
(CB3) terminals. The meter should indicate continuity.
5. Re-connect Wire 2 to the DPE Circuit Breaker (CB2) and reconnect Wire 6 to the Voltage Regulator.
A. Schematic
B. Pictorial
Page 38
Section 7
DIAGNOSTIC TESTS
TEST 4 RESULTS
C
D
VOLTAGE RESULTS
WIRE 2 & 6
EXCITATION WINDING
ABOVE
60 VAC
ABOVE
60 VAC
BELOW
60 VAC
ZERO OR
RESIDUAL
VOLTAGE
(5-12 VAC)
BELOW
60 VAC
BELOW
60 VAC
ABOVE
60 VAC
VOLTAGE RESULTS
WIRE 11 & 22
POWER WINDING
SENSE LEADS
ABOVE
60 VAC
BELOW
60 VAC
ABOVE
60 VAC
ZERO OR
RESIDUAL
VOLTAGE
(5-12 VAC)
BELOW
60 VAC
BELOW
60 VAC
ABOVE
60 VAC
.87-.79 A
20%
.87-.79 A
20%
.87-.79 A
20%
ZERO
CURRENT
DRAW
1.2 A
.87-.79 A
20%
ZERO
CURRENT
DRAW
(MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART Problem 2 on Pages 30 & 31)
6. Disconnect Wire 11 from the Voltage Regulator (VR) and connect one test lead to that wire. Disconnect Wire 22 from the
Voltage Regulator and connect the other test lead to that wire.
Start the generator and measure the AC voltage. It should be
above 60 VAC. Record the results and stop the generator.
7. Re-connect Wire 11 and Wire 22 to the Voltage Regulator.
8. Remove the jumper wire between Wire 4 and 12 volt supply.
9. Set the VOM to measure DC amps.
10. Connect one test lead to the 12 volt fused battery supply Wire
15, and connect the other test lead to Wire 4 (should still be
disconnected from the VR).
11. Start the generator. Measure the DC current. Record the rotor
amp draw.
12. Stop the generator. Re-connect Wire 4 to the Voltage
Regulator.
RESULTS:
Proceed to TEST 4 RESULTS (top of page 40).
Match all results to corresponding column in the
chart. The column letter refers to the Problem 4 flow
charts on pages 28 and 29.
PROCEDURE:
1. Set a VOM to its Rx1 scale.
2. Remove Wire 0 from the Voltage Regulator, fourth terminal
from the top (identified by a negative (-) sign next to terminal).
3. Connect one test lead to Wire 0 and the other test lead to a
clean ground. The meter should read continuity.
4. Disconnect Wire 162 from the Voltage Regulator, sixth terminal
from the top. Disconnect the other end of this wire from the
Excitation Circuit Breaker (CB2). Connect one test lead to one
end of Wire 162 and the other test lead to the other end of the
same wire. The meter should read continuity.
RESULTS:
If continuity was NOT measured across each wire,
repair or replace the wires as needed.
If continuity WAS measured, proceed to Test 6.
Page 39
Section 7
DIAGNOSTIC TESTS
3. Set the Start-Stop Switch to START. During cranking only,
measure DC voltage. It should read 3-5 VDC. Reconnect Wire
4 to the Voltage Regulator. If voltage is measured, it can be
assumed that the Field Boost is working. Stop testing. If voltage is not measured, proceed to Step 4.
4. Test D2 diode: Place a VOM to measure continuity. Place one
test lead on one end of the diode and the other test lead on the
other end. Check for continuity, then reverse the leads and
retest. Continuity should only be measured in one direction,
and when it is measured, it should have a single beep and not
a constant tone. If continuity is measured in both directions
then the diode will need to be replaced. If diode tests good,
proceed to Step 5.
5. Test R2 resistor: Place a VOM to measure resistance.
Disconnect wires going to the terminals of the resistor. Place
the test leads on each terminal of the resistor. Resistance
should be 20 Ohms. If resistance is bad, replace the resistor.
If resistor is good, proceed to Step 6.
6. Test Wire 14: Place a VOM to measure continuity. Disconnect
Wire 14 from the R2 resistor. Unplug the BH2 connector.
Place one test lead on the Wire 14 end that was previously on
the resistor. Place the other test lead on Pin 7 of the BH2 connector. Continuity should be measured. If wire is open,
replace it. If wire is good, disconnect Wire 14 from the circuit
board located on Terminal 11. Place one test lead on this end
and the other test lead on the other BH2 connector Pin 7.
Continuity should be measured. If continuity is not measured,
replace the wire. If continuity is measured, make sure that the
connection on BH2 is good. If the connection appears to be
good, then replace the circuit board.
RESULTS:
1. If field boost voltage checks good in step 3, than replace the
voltage regulator.
2. If field boost is not measured, replace failed parts in Steps 4-6.
Page 40
A. Schematic
B. Pictorial
Section 7
DIAGNOSTIC TESTS
11. Connect the meter test leads across Stator leads Wire 11 and
Wire 33. The reading should be Infinity.
12. Connect the meter test leads across Stator leads Wire 11 and
Wire 66. The reading should be Infinity.
13. Connect the meter test leads across Stator leads Wire 33 and
Wire 66. The reading should be Infinity.
14. Connect the meter test leads across Stator leads Wire 11 and
Wire 2. The reading should be Infinity.
15. Connect the meter test leads across Stator leads Wire 33 and
Wire 2. The reading should be Infinity.
RESULTS:
1. If the Stator passes all steps except Step 7, repair, re-connect
or replace Sensing leads 11 and 22.
2. Replace the Stator if its power windings fail the test. (Note
Result No. 1).
3. If the Power Windings test good, perform the Insulation
Resistance Test on Page 13.
33 & 44
0.184W
22
33
11
22
44
11
22
11
22
A. Schematic
33
44
B. Pictorial
8. Now, set the VOM to its Rx1 K or Rx10,000 scale and zero
the meter.
PROCEDURE:
1. Set a VOM to its Rx1 scale and zero the meter.
10. Connect the meter test leads across Stator lead 33 and
ground. The reading should be Infinity.
3. Connect the VOM test leads across each end of the wire. The
meter should read Continuity.
4. Disconnect Wire 1 from the Rotor Brush Terminal. Connect
Page 41
Section 7
DIAGNOSTIC TESTS
one meter test lead to Wire 1. Connect the other test lead to a
clean ground. The meter should read Continuity.
RESULTS:
1. Repair, reconnect or replace any defective wire(s).
2. If wires check good, go to Test 10.
4
RESULTS:
1. Replace bad brushes. Clean slip rings, if necessary.
2. If brushes and rings are good, go to Test 11.
Page 42
POSITIVE (+)
TEST LEAD
Section 7
DIAGNOSTIC TESTS
RESULTS:
1. Replace the Rotor if it fails the test.
2. If Rotor checks good, perform Insulation Resistance Test, on
Page 14.
PROCEDURE:
Perform this test in the same manner as Test 1, but
apply a load to the generator equal to its rated capacity. With load applied check voltage and frequency.
Frequency should not drop below about 58 Hertz with
the load applied.
Voltage should not drop below about 115 VAC with
load applied.
RESULTS:
1. If voltage and/or frequency drop excessively when the load is
applied, go to Test 14.
2. If load voltage and frequency are within limits, end tests.
11
DISCUSSION:
This test will determine if the generator's rated
wattage/amperage capacity has been exceeded.
Continuous electrical loading should not be greater
than the unit's rated capacity.
CB1
44A
T3
11A
T1
A. Schematic
B. Pictorial
PROCEDURE:
Add up the wattages or amperages of all loads powered by the generator at one time. If desired, a clampon ammeter may be used to measure current flow.
See Measuring Current on Page 16.
RESULTS:
1. If the unit is overloaded, reduce the load.
2. If load is within limits, but frequency and voltage still drop
excessively, complete Test 2, Check/Adjust Engine Governor.
If governor adjustment does not correct the problem, go to
Problem 8 (Flow Chart, Page 35).
DISCUSSION:
The Battery Charge system consists of a center tap
Battery Charge Winding, a Battery Charge Rectifier,
and a Battery Charge Resistor. During normal operation the battery charge output will vary between 1 to 2
amps, depending on the load applied to the generator.
PROCEDURE:
1. Disconnect Wire 15 from the Battery Charge Rectifier (center
terminal). Wire 15 is the fused battery supply.
DISCUSSION:
If engine speed appears to drop off excessively when
electrical loads are applied to the generator, the load
voltage and frequency should be checked.
Section 7
DIAGNOSTIC TESTS
approximately 0.8 Amps. Apply full load to the generator. The
amp reading should increase to approximately 2 Amps.
RESULTS:
1. If amperage was measured between 0.8 to 2 Amps in Step 2
and Step 3, the charging system is working.
2. If no amperage was measured, check the VOM fuses and verify the functioning of the Amp Meter. If DC Amp Meter is good
and no current is measured, go to Test 16
RESULTS:
1. If any of the previous steps has failed, replace the Battery
Charge Rectifier.
PROCEDURE:
1. Disconnect Wire 66, Wire 15 and Wire 77 from the Battery
Charge Rectifier.
PROCEDURE:
1. Disconnect the Stator Leads (Wire 66 and Wire 77) from the
Battery Charge Rectifier. (Be sure to disconnect Stator Lead
Wire 66 Black from Wire 66 Blue connector for this test).
Disconnect the Stator Lead Wire 55 from the Battery Charge
Resistor.
2. Set the VOM to the Diode Test range. Connect the negative (-)
test lead to the center terminal of the BCR. Connect the positive (+) test lead to an outer terminal. The meter should measure approximately 0.47 to 0.5 volts.
3. Connect the positive (+) test lead to the center terminal of the
BCR. Connect the negative (-) test lead to to an outer terminal.
The meter should measure Infinity. Connect the negative test
lead to the other outer terminal. Infinity should once again be
measured.
3. Connect one test lead to Stator Lead Wire 77. Connect the
other test lead to Stator Lead Wire 55. Normal Battery Charge
Winding resistance should be measured.
Short to Ground:
4. Set the VOM to measure resistance. Connect the positive (+)
test lead to the case housing of the BCR. Connect the negative
(-) test lead to an outer terminal. Infinity should be measured.
Now connect the negative test lead to the BCR center terminal.
Infinity should be measured. Next, connect the negative test
lead to the remaining outer BCR terminal. Once again Infinity
should be measured.
66
15
77
4. Connect one test lead to Stator Lead Wire 55. Connect the
other test lead to Stator Leads Wire 11 & 33 at the back of
CB1. Infinity should be measured.
5. Connect one test lead to Stator Lead Wire 55. Disconnect
Stator Lead Wire 2 from the DPE circuit breaker (CB2) and
connect the other test lead to Wire 2. Infinity should be measured.
6 Connect one test lead to Stator Lead Wire 55. Connect the
other test lead to frame ground. Infinity should be measured.
7. Connect one test lead to the Battery Charge Resistor terminal
that Wire 55 was removed from. Connect the other test lead to
frame ground. One (1) ohm should be measured. If 1 ohm was
not measured, remove Wire 0 from the Battery Charge Resistor.
Connect one test lead to Wire 0 and the other test lead to frame
ground. Continuity should be measured. Repair or replace
Wire 0 if defective and retest the Battery Charge Resistor.
BATTERY CHARGE WINDING RESISTANCE *
QP75D (Model 4270)
ACROSS WIRES:
OHMS
55 & 66
0.7
55 & 77
0.5
Section 7
DIAGNOSTIC TESTS
* Resistance values in ohms at 20 C. (68 F.). Actual readings
may vary depending on ambient temperature. A tolerance of
plus or minus 5% is allowed.
RESULTS:
1. For Steps 2 & 3, keep in mind that the resistance values are
very low. Depending upon the quality of the VOM, it may read
Continuity across these windings. Exercise good judgement
with these values.
2. If Steps 2, 3, 4, 5 & 6 fail any test, replace the Stator.
3. In Step 7, if Wire 0 reads Continuity, but resistor does not
measure 1 ohm, replace the Battery Charge Resistor.
4. If all of the Steps in this test pass, perform Insulation
Resistance Test on page 13.
DISCUSSION:
If the Pre-Heat Switch on the generator panel is actuated, but the Fuel Pump does not run (priming function doesn't work), perhaps battery voltage is not
available.
150
15
150
150
B. Schematic
PROCEDURE:
Hold the Start-Stop Switch at START. The engine
should crank and start.
RESULTS:
1. If the engine cranks normally, but the pre-heat function still
doesn't work, go to Test 19.
2. If engine will not crank, go to Test 21. Refer to Problem 6 of
Section 6.
3. If engine cranks but won't start, go to Problem 7 of Section 6.
4. If engine starts hard and runs rough, go to Problem 8 of
Section 6.
15
A. Pictorial
Page 45
Section 7
DIAGNOSTIC TESTS
PROCEDURE:
1. Set a VOM to measure DC voltage.
2. Disconnect the connector from the wires of the fuel pump.
3. Place the positive (+) test lead on Wire 14 and the negative (-)
test lead to clean ground. Press the pre-heat switch, battery
voltage should be measured, if not, disconnect the other end of
Wire 14. Place test leads on each end of Wire 14. Set a VOM
to measure continuity. Continuity should be measured.
4. Disconnect Wire 0 from the black wire of the fuel pump. Place
one test lead on Wire 0 and the other test lead to ground.
Continuity should be measured. If continuity is not measured,
replace Wire 0.
5. Jump 12 VDC to white wire of fuel pump, and jump black wire
to clean frame ground. Fuel pump should pump.
RESULTS:
1. If battery voltage and continuity are not measured in step 3,
then replace bad wire.
2. If pump does not pump in step 5, replace the pump
Page 46
DISCUSSION:
If battery voltage is not available to the circuit board,
engine cranking and running will not be possible.
If battery voltage is available to the board, but no DC
output is delivered to the board's Wire 56 terminal
while attempting to crank, either the circuit board is
defective or the Start-Stop Switch has failed.
This test will determine if battery voltage is available
to the Engine Controller circuit board. Test 24 will
check the Start-Stop Switch. Test 25 will check the
DC power supply to the circuit board's Wire 56 terminal (Receptacle J1, Pin 1).
PROCEDURE:
1. On the Engine Controller Circuit Board, locate Terminal 1 to
which Wire 15 connects (see chart on Page 24).
2. Set a VOM to read battery voltage. Connect the meter test
leads across circuit board Terminal 1 and ground. The meter
should read battery voltage.
Section 7
DIAGNOSTIC TESTS
3. Set the VOM to measure resistance (Rx1 scale). Connect
one meter test lead to Wire 0, Terminal 2 on the Engine
Controller Circuit Board. Connect the other test lead to a clean
frame ground. Continuity should be measured.
PROCEDURE:
For Problem 6 (Section 6), perform all steps. For
Problem 9, perform Step 1 and Step 5 ONLY.
1. Set a VOM to its Rx1 scale and zero the meter.
RESULTS:
1. If battery voltage is NOT indicated in Step 1, check continuity of:
a.
b.
c.
d.
INFINITY
NOT ACTIVATED
INFINITY
INFINITY
18
DEPRESSED
AWAY FROM
TERMINAL BEING
TESTED
CONTINUITY
18
0
SW1
17
17
CONTINUITY
INFINITY
DEPRESSED
AWAY FROM
TERMINAL BEING
TESTED
Page 47
Section 7
DIAGNOSTIC TESTS
RESULTS:
1. If Continuity is not measured in Step 2, repair, reconnect or
replace Wire 0 (between Start-Stop Switch and ground terminal) as necessary.
2. If engine cranks in Step 3 when Wire 17 is grounded, but will
not crank when the Switch is set to START, replace the StartStop Switch.
3. If the Start-Stop Switch (SW1) failed any part of Steps 5 or 6,
replace the switch.
4. If engine will not crank when Wire 17 is grounded, proceed as
follows:
a. Use a jumper wire to connect the circuit board's
Wire 17 (Pin Location 3) to ground. If engine
does NOT crank, proceed to Test 25.
b. If engine cranks now, but would not crank in
Step 3 of the procedure, check Wire 17 for continuity between the circuit board and Start-Stop
Switch. If Continuity is not measured, repair or
replace Wire 17 between the engine control
board and the Start-Stop Switch.
5. For Problem 9 (Section 6), if switch tests GOOD, go to Test 30.
Page 48
Section 7
DIAGNOSTIC TESTS
b. Open armature (wire broken) will be indicated
by low or no RPM and excessive current draw.
c. Grounded armature (wire insulation worn and
wire touching armature lamination or shaft). Will
be indicated by excessive current draw or no
RPM.
3. A defective Starter Motor switch.
4. Broken, damaged or weak magnets.
5. Starter drive dirty or binding.
DISCUSSION:
Test 25 verified that circuit board action is delivering
DC voltage to the Starter Contactor Relay (SCR).
Test 26 verified the operation of the Starter Contactor
(SC). Another possible cause of an "engine won't
crank" problem is a failure of the Starter Motor.
PINION
Page 49
Section 7
DIAGNOSTIC TESTS
TEST BRACKET:
A starter motor test bracket may be made as shown
in Figure 7-18.
REMOVE STARTER MOTOR:
It is recommended that the Starter Motor be removed
from the engine when testing Starter Motor performance. Assemble starter to test bracket and clamp
test bracket in vise (Figure 7-19).
TESTING STARTER MOTOR:
1. A fully charged 12 VDC battery is required.
2. Connect jumper cables and clamp-on ammeter as shown in
Figure 7-19.
3. With the Starter Motor activated (jump the terminal on the
Starter Contactor to battery voltage), note the reading on the
clamp-on ammeter and on the tachometer (rpm).
4500
50
2"
STARTER
CONTACTOR
3.5"
CLAMP ON
AMP METER
STARTER
MOTOR
1.75
3.5"
4"
2"
1.5"
15"
TACHOMETER
VISE
12 VOLT
BATTERY
3"
Section 7
DIAGNOSTIC TESTS
RESULTS:
1. If necessary, replenish fuel supply.
2. If fuel is good, proceed to test 29.
18
PROCEDURE:
1. Set a VOM to read battery voltage (12 VDC).
2. If Continuity was measured in Step 3, repair or replace shorted Wire 18 between J1 Connector and remote panel connector.
2. Connect the meter positive (+) test lead to Pin 9 on the PCB,
the common (-) test lead to ground.
3. Crank the engine and the meter should read battery voltage.
RESULTS:
1. If the meter indicated battery voltage, go to Test 19.
2. If battery voltage was NOT indicated in Step 3, replace the
Engine Controller Circuit Board.
DISCUSSION:
Wire 18 controls sending the STOP signal to the
Engine Controller Circuit Board. If Wire 18 contacts
ground it will initiate a shutdown. Coach manufacturers sometimes install a 15 to 30 foot remote harness.
A ground on Wire 18 in a remote harness can also
cause a shutdown.
PROCEDURE:
1. Remove the remote harness connector from the generator and
3. Place the positive (+) test lead on Wire 14 and the negative (-)
test lead on clean ground.
4. Press the prime switch, battery voltage should be measured. If
measured, skip to Step 8. If not, proceed to next Step.
Page 51
Section 7
DIAGNOSTIC TESTS
6. Place test leads on each end of wire, continuity should be
measured.
Page 52
Section 7
DIAGNOSTIC TESTS
PROCEDURE:
1. Remove the valve cover from engine.
2. Disconnect the battery.
3. Manually turn flywheel until cylinder #1 (furthest from flywheel)
is at top dead center (TDC) and adjust the clearances of the
intake and exhaust valves of the No. 1 cylinder and the
exhaust valve of the No. 2 cylinder.
MARK AT
TOP DEAD CENTER
ADJUSTMENT
SCREW
DISCUSSION:
The fuel injector pump takes the fuel that is provided
by the electric fuel pump, and delivers it to the fuel
injector nozzles. Given that the fuel solenoid is operating correctly and the linkage from the governor is
not binding, the fuel injector pump will need little to no
maintenance.
PROCEDURE:
1. If fuel injector pump is assumed to being faulty, remove the
fuel lines going to the nozzle injectors.
2. Prime the engine for 15-20 seconds.
3. Crank the engine and watch to see if fuel is coming out of the
fuel lines.
JAM NUT
Page 53
Section 7
DIAGNOSTIC TESTS
8. Crank engine again and see if fuel is coming out of the fuel
lines.
RESULTS:
1. If no fuel is noted in Steps 3 or 8, replace fuel injector pump.
(Reinstallation of all original shims will be required.)
2. If fuel is noted, proceed to next step in flowchart.
Page 54
Section 7
DIAGNOSTIC TESTS
NOTE: For units out of warranty, refer to
Quicksilver Diagnostic & Service Manual - Diesel,
P/N 082034 for further engine service information.
This manual can be found at www.guardiangenerators.com, under Brochures,Manual & Specs Recreational Vehicle - Manuals.
RESULTS:
1. In Step 3, if Continuity is not indicated, replace the switch.
2. If oil pressure checked good in Step 5, but Step 4 measured
Infinity, replace the low oil pressure switch.
3. If oil pressure is below 10 psi, determine cause of low oil pressure. Refer to Engine Service manual No. 0E2081 for further
engine service information. Verify that the oil is the proper viscosity for the climate and season.
4. If all steps check GOOD, go to Test 40.
RESULTS:
1. If continuity was not measured in step 3, replace wire.
2. If continuity was measured in step 3, replace the circuit board.
Section 7
DIAGNOSTIC TESTS
RESULTS:
1. If continuity is measure, replace the switch.
2. If infinity is measured, proceed to next test on the flow chart.
Page 56
Section 8
ASSEMBLY
MAJOR DISASSEMBLY
11. Remove the two hold down bolts mounting the brush assembly to the rear-bearing carrier.
STATOR/ROTOR/ENGINE REMOVAL:
After the panel assemblies are removed, the tech will
have full access to the components of the unit for
easier removal.
STATOR:
1. Remove the front belt tensioner by using a " socket and
wrench.
2. Loosen bolt and nut and remove.
3. Use a 16-mm socket for the rear tensioner.
4. Remove the rear and front belts.
5. Remove the two screws mounting the electric fuel pump to the
bottom frame by using a 10-mm socket.
6. Disconnect the wiring harness from the fuel pump.
13. Using a 13-mm, remove the four stator hold down bolts. The
bottom two run through the rear cross member frame. With the
bottom two removed, the rear cross member will be able to be
removed.
14. Using a rubber mallet, tap off the rear-bearing carrier.
15. Remove the stator (be careful, not to hit the battery charge
resistor).
ROTOR:
1. Use a prybar to stabilize the rotor pulley and loosen from rotor
bolt.
2. Using a rubber mallet, tap off the rotor pulley.
3. Remove the rotor.
The front bearing carrier is now available for removal
as well.
ENGINE:
In order for the engine to be removed, the flywheel
will need to be removed first.
1. Using a prybar, stabilize the flywheel and remove the 6 bolts
mounting the flywheel to the engine.
7. Remove air filter and rubber hose from the metal cross member frame by using a flat tip screwdriver.
2. Remove flywheel.
8. Place a block of wood under the rear of the engine for support.
3. Remove rubber fuel lines mounting to the top of the fuel injector pump.
10. Remove the four bolts that mount the engine to the cross
member.
Page 57
Section 8
ASSEMBLY
4. Attach a hoist hook to the top lifting bracket attached to the
engine.
5. Slightly lift the engine to take pressure off of the block of wood.
3. With the coolant drained, lower the unit and remove the lower
and 2 upper coolant hoses.
RE-ASSEMBLY
To re-assemble the generator, reverse the previous
procedures.
BELT TENSIONING
DRIVE BELT:
1. Install drive belt tensioner as shown in Figure 8-4. Snug mounting bolt but do not tighten.
2. Using a 3/4 wrench, apply tension to the belt as shown in
Figure 8-5.
RADIATOR REMOVAL:
Prior to removing the radiator, the top panel will need
to be removed.
Page 58
Section 8
ASSEMBLY
LINE UP ARROW
WITH 15 MARK
LINE CORNER
UP BETWEEN
5 to 10
Page 59
Section 9
Exploded Views / Part Numbers
32
24
21
1
2
23
21
25
26
41
42
45
22
Page 60
22
20
38
50
13
39
49
26
11
44
49
28
40
36
21 37
19
29
28
43
21
17
10
39
27
26
25
31
35
18
14
33
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
QTY.
1
1
1
1
1
1
1
2
4
6
1
1
1
1
1
1
1
1
2
2
8
8
2
1
4
6
2
2
1
1
1
11
6
2
5
1
2
1
4
1
4
3
1
2
1
2
1
1
2
2
DESCRIPTION
Bearing Carrier, Front
Bearing Carrier, Upper
Rotor Assembly
Stator Assembly
Ball Bearing
Ball Bearing
Brush Holder
Taptite M5-0.8 x 16mm
Bolt , Stator
5/16 Special Lock Washer
Lug, Lift
Rail, Engine RH
Pulley, 4.5" Flat
Belt, V-Rib
Starter Motor
Spacer, Starter
Pulley, Alternator
Flywheel Assembly
HHCS M8-1.25 x 55mm
Washer, Vibration Isolator
Washer, Split Lk -M8
Nut, Hex M8-1.25
SHCS 5/16"-18 x 1-1/2"
Guard, Flywheel
HHCS M12-1.25 x 20mm
Washer, Split Lk -M12
Engine Bracket
" Flat washer
"-13 x 4" HHCS
Fender Washer 7GA
HHCS 3/8-24 x 1"
Lockwasher M10
HHCS M10-1.25 x 25mm
5/16 Flange Nut
HHCS M10-1.25 x 20mm
M6 Hex Nut
HHCS M8-1.25 x 25mm
Earth Strap
HHCS M8-1.25 x 20mm
" Special Lock Washer
M8 Flange Nut
Taptite, M6-1.0 x 8mm
Engine, 1.0L Diesel
Washer, Flat M12
Clamp, Vinyl Coated, 1-1/16"
HHCS M12-1.25 x 25mm
Tensioner, SE-F18-4.5"
"-13 x1-3/4" HHCS
"-13 Flange Nut
Flat Washer, 5/16"
Page 61
Section 9
Exploded Views / Part Numbers
Base Frame Drawing No. 0D2357-A
11
12
8
7
1
7
16
17
17
6
18
23
22
13
15
19
17
9
20
21
2
5
10
13
4
14
Page 62
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
QTY.
1
1
1
4
2
677mm
4
4
1
1
8
8
3
2
1
1
3
2
2
1
1
1
1
DESCRIPTION
Base Frame Weldment
Door, Service Rear
Door, Service Front
Slide Latch Flush
Vinyl Trim -Black 180mm
Rubber Tape 1/8 x "
Grommet 1/8 x 13/32
Vibration Mount
Gasket, Cleanout
Plate, Cleanout
HHCS M8-1.25 x 16
Washer, Split Lk- M8
Washer, Split Lk -1/4-M6
HHCS M6-1.00 x 10
Carriage Bolt 3/8 -16 x 55mm
3/8 Special Lock Washer
Hex Nut 3/8-16 Brass
HHCS M6-1.00 x 16
Nut, Hex M6.0 -1.0
Block, Terminal Battery Post
Stud 3/8-16 x 55mm
Washer 3/8 Flat
Washer Split Lk -3/8
mm = Millimetres
Page 63
Section 9
Exploded Views / Part Numbers
Enclosure Drawing No. 0D2358-D
25
12
17
11
24
17
17
2
13
20
34
VIEW "A"
27
10
17
17
1
30
38
32
9
31
26 22
35
8
14
5
15 17
28
21
A
18
33
29
16
19
2
23
7
17
17
36
37
17
4
3
17
Page 64
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
33
57
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
3
1
1
2
2
1
DESCRIPTION
Enclosure Panel RH
Enclosure Panel Top
Enclosure Panel LH
Enclosure Panel Front
Enclosure Rear Panel
Insulation, Front Panel
Insulation, LH Side Panel
Insulation, RH Side Panel
Insulation, Top Front Panel
Insulation, Top Rear Panel
Insulation, Lifting Lug Cover
Cover, Access Lift
Cover, Radiator Fill
Cover, Access Electrical
Gasket, Electrical Access
Washer, Self Locking
-20 x 5/8 W/Washer
Frame Control Panel - Refer to Drawing C8005
Decal, Battery +/Decal, Radiator Cap
Decal, Remote
Decal, Coolant
Decal, Fuel Return/Supply
Decal, Oil Fill / Level
Decal, Lifting Lug
Decal, Max Hot / Min Coolant
Decal, Warning Rv
Support, Coolant Tank
Nut, Hex M6-1.0
Foam, Air Duct Face
Foam, Air Duct Side
Decal, Unit
Washer, Split Lock " - M6
Decal, Engine Data
Decal, CSA Approval
Washer Nylon 0.250"
Screw SW "-20 X 3/8" Long
Clamp Vinyl 1.5" X 0.281"
Page 65
Page 66
30
12
46
42
25
40
47
34
29
27
25
5 42
43
34
51
33
48 25
44
45
28
34
36
4
41
34
32
41
31
19
18
49
39
14
21
38
37
21 20
15
23
50 (RE
4
17
14 13
39
54
14
5 53
18
22
55
26
1
9
10
11
Section 9
Exploded Views / Part Numbers
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
49
51
52
53
54
55
QTY.
1
1
1
1
1
1
1
1
1
1
1
7
2
7
4
4
4
12
1
3
5
1
1
2
6
1
1
1
1
1
1
1
1
8
2
720mm
1
1
2
270mm
4
4
1
1
510mm
2
1
1
1
1
1
1
1
DESCRIPTION
Cover Plate, Scroll Weldment
Housing, Fan Scroll Weldment
Fan, Squirrel Cage
Shaft, Fan
Carrier, Bearing
Key, Square 3/16" x 3/16" x "
Pulley, Fan 4-7/8"
Bearing 2 Row Ball
Fender Washer M16
Nut, Hex M16.0 -1.5mm
LockWasher M16.0
Crimptite, "-20 x 5/8"
HHCS M6-1.00 x 10mm
Washer, Split Lk "- M6
HHCS M5-0.8 x 16mm
Washer, Split Lk #10
Hex Nut M5
Nut Top Lock Flange M6-1.0
Radiator 1.0L RV
HHCS M6-1.00 x 12mm
Washer "-M6
Pulley, 3" Flat Flanged
Bracket, Rotary Tensioner
HHCS M8-1.25 x 20mm
Washer, Split Lk -M8
61" Green Belt
Filler Neck Assembly, Radiator Remote
Hose Tee
Coupling, Hose
Hose, Radiator Lower
Hose, Water Pump Lower
Hose, Top
Hose, Lower Intermediate
Hose Clamp Hi Trq 1-3/4" Max
Hose Clamp #12
Hose, " SAE-20R3
M10-1.5 x 30mm HHCS
M10 Lockwasher
HHCS M6-1.00 x 16mm
Hose, 5/16" SAE-20R4
Hose Clamp 7/8" 3/8"
HHCS M8-1.25 x 16mm
Cap, Coolant Fill
Tank, Coolant Overflow
Hose 5/16" SAE-20R4
Clamp, Vinyl Coated 1-5/8"
Cap, Radiator Pressure
Gasket, Radiator Base
Nut, Hex M8-1.25
Bracket, Support
"-13 x 1-" HHCS
Tensioner, SE-18-3"
"-13 Flange Nut
mm = Millimeters
Page 67
Section 9
Exploded Views / Part Numbers
12
14
28
Page 68
17
19
16
13
31
25
11
26
27
29
28
28
27
4 15
11
25 26
27
18
32
20
33
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
31
32
33
QTY.
1
1
1
1
1
1
1
A/R
2
1
3
2
4
1
1
1
4
1
4
1
*1
*1
*1
*1
2
2
7
7
3
4
1
1
DESCRIPTION
Weldment, Electrical Enclosure
Terminal Block 4 Position
Assembly, Potted Regulator
Resistor 20R 5% 12W
Assembly Marine Control Board
Rectifier, Battery Charging
Circuit Breaker 5 Amp
Tape, Glass Insulated
Taptite, M5-0.8 x 30
Taptite, M5-0.8 x 16
Lockwasher M5
Nut, Hex M4-0.7
Pcb Support Snap -In
HHMS, #8-32 x 2.25"
Washer, Flat M5
Harness
M4-0.7 x 16 HHCS Taptite
Decal, Customer Connection
Washer, Flat #8
Gasket, Electrical Enclosure
Wire Assembly # 32
Wire Assembly # 22
Diode Assembly
Wire Assembly # 162
Special Lockwasher
Washer, Flat -M6
Washer, Split Lk -M6
Nut, Hex M6-1
Bushing, Snap
HHCS, M4-0.7 x 16mm
Gasket, Electrical Enclosure Divider
Harness, Ac Output
A/R = As Required
* Not shown refer to Wiring Diagram C4946
Page 69
Section 9
Exploded Views / Part Numbers
Intake and Exhaust System Drawing No. 0D2362-B
16
6
22
15
24
23
15
22
15
27
19
21
10
26
19
20
15
28
16
25
13
TO ENGINE AIR INTAKE
4
9
7
11
17
15
12
14
16
Page 70
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
QTY.
1
1
1
1
1
2
1
1
3
1
1
1
2
2
10
5
3
1
4
2
4
2
1
1
2
1
1
1
1
DESCRIPTION
Exhaust Gasket
Chamber Air Intake
Air Filter
Hose, Air Inlet
Muffler Weldment
U Bolt & Saddle 1.25
Rail, Engine LH, Weldment
Insulation, Exhaust
Hose Clamp #28
Outlet, Exhaust Flex
Gasket, Exhaust Outlet
Plate, Exhaust Outlet
HHCS M8-1.25 x 55
Washer, Vibration Isolator
Washer, Split Lk -M8
Nut, Hex M8-1.25
Crimptite, "-20 x 5/8"
Bracket, Support
Washer, Flat - M8
HHCS M8-1.25 x 20
HHCS M8-1.25 x 25
Hose Clamp #20
HHCS M8-1.25 x 30
HHCS M8-1.25 x 16
Flatwasher, 5/16"
Manifold Gasket
Horizontal Exhaust Manifold
Grommet 1-3/4" x 1/8" x 2"
WASHER FLAT 0.336"ID X 0.876"OD
Page 71
Page 72
17
17
TO GLOW PLUGS
16
26
TO STARTER MOTOR
29
23
16
10
TO STARTER
MOTOR BOLT
20
25
21
16
7
18
14
17
12
27
15
13
4
19
26
25
22
12
10
24
5 4
11
27
28
1 2 12
TO GROUND
TO STATOR
Section 9
Exploded Views / Part Numbers
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
QTY.
1
3
2
7
1
2
5
1
5
2
1
3
1
1
1
3
3
2
1
1
1
1
1
1
1.04M
635mm
375mm
1
1
DESCRIPTION
Fuel Pump Assembly
1/8 NPT x 5/16 Barbed Straight Fitting
Bulkhead Adaptor Fitting
Washer, Split Lk- -M6
HHCS M6-1.00 x 30
Relay Solenoid
Nut, Hex M6-1
Clamp, Vinyl Coat 1-1/16"
Washer, Flat -M6
Hose Clamp
1/8 NPT x 1/4 Barbed Straight Fitting
Hose Clamp 7/8 / 3/8
HHCS M6-1.00 x 16
Hex Nut 3/8-16 Brass
Washer Split Lk 3/8
Boot, Battery Cable
Boot, Battery Cable
Snap Bushing 1"
Hex Nut - 20
Cable, Battery
Cable, Starter
HHCS M6-1 x 65
Wire Assembly, Black #4 Ground
Resistor
Hose, 1/4 ID SAE-30R7
Hose, 5/16 ID SAE-30R7
Hose, 5/16 ID SAE-30R7
Clamp, Fuel Pump
Wire Assy, #0 (PHC-SC)
M = Meters
mm = Millimetres
Page 73
Section 9
Exploded Views / Part Numbers
26
28
Page 74
25
31
22
15
22
26
21
19
13
16
24
21
23
27
12
11
30
17
29
18
32
33 3
34
10
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
QTY.
1
1
1
1
1
2
2
1
1
1
4
1
1
2
1
1
1
1
1
1
2
2
4
4
1
2
1
2
4
4
2
4
1
1
DESCRIPTION
Start / Stop Switch
Cover, Engine Control Box
Hour Meter
Fuse Holder, SFE-14
Switch, Pushbutton SPST
PPHMS M3-0.5 x 10
Lockwasher M3
Fuse, SFE-14
Decal
Boot / Nut / Preheat Switch
Lockwasher, M5
Boot, Circuit Breaker
Harness
Hex Nut, M3
Box, Engine Control
Frame, Control Panel
Plug, Oil Fill
Dipstick Assembly
Hose, Dipstick Tube
Hose, Filler Tube
Hose Clamp 7/8-3/8
Hose Clamp Size #16
M4-0.7 x 16 HHCS Taptite
Washer, Flat #6
Grommet
Gasket, Engine Control Box
Circuit Breaker, 35A, 2 Pole
Nut, Hex M6-1.0
PHMS M5-0.8 x 12
Flatwasher, #8
Washer, Split Lock " - M6
Screw, PPHM #6-32 x 1/4"
Gasket, Hourmeter
Gasket, Switch
Page 75
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Camshaft Drawing No. 075677
1
3
6
5
4
10
13
7
12
11
8
9
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
Page 76
QTY.
1
1
1
1
3
1
1
1
1
1
1
1
1
DESCRIPTION
CAMSHAFT ASSEMBLY
CAMSHAFT GEAR
KEY
GEAR
SPACER
BALL BEARING
SLIDER
PLATE
TACHOMETER SHAFT
BOLT
BOLT
GASKET
NUT
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Cylinder Block Drawing No. 075676
15
28
5
13
19
27
12
18
23
17
16
5
24
20
25
21
14
3
26
30
11
29
10
2
ITEM
QTY.
1
2
3
4
5
6
7
8
9
10
11
1
1
1
2
2
1
4
4
1
1
1
1
1
1
1
1
1
12
13
14
15
DESCRIPTION
COMPLETE CYLINDER BLOCK
EXPANSION PLUG
EXPANSION PLUG
EXPANSION PLUG
EXPANSION PLUG
EXPANSION PLUG
PLUG
PLUG
IDLE GEAR SHAFT
BUSHING
BUSHING-STANDARD
0.25MM U.S. BUSHING
0.50MM U.S. BUSHING
BALL BEARING
EXPANSION PLUG
BALL BEARING
DOWEL PIN
22
ITEM
QTY.
DESCRIPTION
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
2
2
1
1
1
1
1
1
1
6
6
1
1
DOWEL PIN
DOWEL PIN
SPRING PIN
STUD
STUD
STUD
SNAP RING
OIL SEAL
DRAIN COCK
CONNECTOR
OIL FILTER
TAPPET
PUSH ROD
RELIEF VALVE
O-RING
MM = MILLIMETER
U.S. = UNDERSIZE
Page 77
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Cylinder Head Drawing No. 0D2794
11
10
3
13
14
2
20
1
4
22
21
18
4
23
19
17
16
5
12
ITEM
QTY.
1
2
3
4
5
6
7
1
6
3
2
3
3
3
3
6
6
12
6
1
8
9
10
11
12
Page 78
DESCRIPTION
CYLINDER HEAD ASSEMBLY
EXPANSION PLUG
EXPANSION PLUG
XPANSION PLUG
INTAKE VALVE
EXHAUST VALVE
VALVE GUIDE SEAL (EXHAUST)
VALVE GUIDE SEAL (INTAKE)
SPRING
RETAINER
KEY
CAP
CYLINDER HEAD GASKET,
1.2MM THICK
CYLINDER HEAD GASKET,
1.3MM THICK
ITEM
QTY.
13
14
15
16
17
18
19
20
21
22
23
11
3
2
2
1
2
1
1
4
1
1
DESCRIPTION
BOLT
BOLT
LIFTING EYE
BOLT
TUBING
BOLT
OIL SWITCH
THERMO-SWITCH
GASKET
WASHER
ADAPTOR
MM=MILLIMETER
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Crankshaft, Piston and Flywheel Drawing No. 075679-B
19
17
16
18
19
22
20
21
11
11
12
13
10
15
10
14
1
4
2
28
30
ITEM
QTY.
1
2
3
4
5
6
7
8
9
10
11
1
1
1
1
1
1
1
1
6
6
3
AR
AR
3
AR
AR
2
2
1
3
AR
AR
12
13
14
15
16
DESCRIPTION
CRANKSHAFT ASSEMBLY
CRANKSHAFT GEAR
KEY
DOWEL PIN
SPRING PIN
BEARING HOLDER ASSEMBLY
BEARING HOLDER ASSEMBLY
BEARING HOLDER ASSEMBLY
BOLT
DOWEL PIN
STANDARD BEARING
0.25MM U.S. BEARING
0.50MM U.S. BEARING
STANDARD BEARING
0.25MM U.S. BEARING
0.50MM U.S. BEARING
THRUST WASHER
BOLT
BOLT
STANDARD PISTON ASSEMBLY
PISTON ASSEMBLY-0.5MM O.S.
PISTON ASSEMBLY-1.0MM O.S.
ITEM
QTY.
17
3
AR
AR
3
6
3
3
6
6
6
AR
AR
1
1
18
19
20
21
22
23
24
28
30
DESCRIPTION
STANDARD PISTON RING SET
PISTON RING SET-0.5MM O.S.
PISTON RING SET-1.0MM O.S.
PISTON PIN
SNAP RING
CONNECTING ROD ASSEMBLY
BUSHING
CONNECTING ROD BOLT
NUT, CONNECTING ROD BOLT
STANDARD BEARING
BEARING-0.25MM U.S.
BEARING-0.50MM U.S.
PULLEY
NUT
U.S. - UNDERSIZE
O.S. - OVERSIZE
AR - AS REQUIRED
MM - MILLIMETER
Page 79
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Oil Pump Drawing No. 75682
11
10
5
7
3
12
2
4
6
8
ITEM
QTY.
1
2
3
4
5
6
1
1
1
1
1
AR
AR
AR
AR
1
1
1
1
1
3
7
8
9
10
11
12
AR - AS REQUIRED
Page 80
DESCRIPTION
IDLER GEAR ASSEMBLY
SPRING
THRUST WASHER
ROTOR
OIL PUMP COVER
0.10MM SHIM
0.15MM SHIM
0.20MM SHIM
0.50MM SHIM
SPRING
COLLAR
SNAP RING
FRONT PLATE
GASKET
BOLT
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Rocker Arm Assembly Drawing No. 075683
4
5
11
6
2
3
8
12
7
9
10
ITEM
QTY.
2
3
4
5
6
7
8
9
10
11
12
3
3
6
6
3
1
2
2
3
3
3
DESCRIPTION
ROCKER ARM ASSEMBLY
(INCLUDES ALL COMPONENTS SHOWN BELOW)
INTAKE ROCKER ARM
EXHAUST ROCKER ARM
NUT
STUD
ROCKER ARM BRACKET
ROCKER ARM SHAFT
SPRING
SCREW
SPRING,PIN
NUT
STUD
Page 81
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Injector Pump Drawing No. 075686-C
11
9
12
10
14
3
13
19
(MODEL 04270
& 04614 ONLY)
5
18
29
28
20
19
27
17
26
4
1
16
2
ITEM
QTY.
1
2
1
AR
AR
AR
AR
3
2
3
3
3
3
1
1
1
1
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
INJECTOR PUMP ASSEMBLY
SHIM-0.2MM
SHIM-0.3MM
SHIM-0.5MM
SHIM-1.0MM
NUT
BOLT
GASKET
INSERT
CAP
INJECTOR
TUBING
TUBING
TUBING
TUBING
ITEM
QTY.
13
14
16
17
18
19
1
1
3
1
1
1
1
20
26
27
28
29
2
1
1
1
1
DESCRIPTION
CLAMP
BOLT
GLOW PLUG
CONNECTOR
GASKET
COVER (ALL MODELS EXCEPT
04270 & 04614)
TUBE, ENGINE OIL FILL (MODEL
04270 & 04614)
BOLT
SOLENOID
WASHER
WASHER
SCREW
AR - AS REQUIRED
Page 82
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Fuel Supply Drawing No. 075693-C
14
10
To Fuel
Tank (Return)
14
14
11
19
(Model 04270 & 04614)
10
9
17 13
15
16
16
5
18
5
16
17
8
6
7
18
2
5
To Injection Pump
3
To Fuel Pump
ITEM
QTY.
1
2
3
4
5
6
7
8
9
10
1
1
AR
250MM
3
2
1
1
2
2
DESCRIPTION
FUEL FILTER SUPPORT
FUEL FILTER
HOSE, 5/16" SAE 30R7
HOSE, 5/16" SAE 30R7
HOSE CLAMP
GASKET
BANJO FITTING
FUEL BLEED FITTING
1/8" NPT TEE (BRASS)
1/8" NPT x 3/16" 90 DEG. BARBED
FITTING
ITEM
QTY.
11
2*
12
13
14
15
16
17
18
19
275MM
240MM
4
1
5
2
2
1
DESCRIPTION
1/8" NPT x 3/16" BARBED STRAIGHT
FITTING
HOSE, 3/16" SAE 30R2
HOSE, 3/16" SAE 30R2
HOSE CLAMP
FUEL BLEED FITTING
FUEL BLEED GASKET
HOLLOW BOLT
BANJO FITTING
1/8" NPT x 1/4" BARBED STRAIGHT
FITTING (MODEL 04270 & 04614)
Page 83
Page 84
50
49
48
44
47
45
43
42
42
37
40
36
35
13
38
46
13
21
23
52
22
51
18
8
24
27
19
39
26
28
25
13
14
33
31
30
20
15
34
32
29
16
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Timing and Governor Drawing No. 082067-B
Section 9
Exploded Views / Part Numbers
ITEM
1
2
3
4
5
6
7
8
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
QTY.
1
1
1
1
1
2
1
2
1
1
1
1
1
1
3*
5
1
4
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
2
1
1
1*
1*
1
1*
1*
1*
1*
3*
1
3
1
4
4
DESCRIPTION
HOUSING, TIMING GEAR
SPRING PIN
GASKET
SPRING
WASHER
NUT
STOP LEVER
COVER
GOVERNOR LEVER
BOLT
NUT
SHAFT
O-RING
SNAP RING
BOLT
BOLT
OIL SEAL
BOLT
BOLT
ARM
SNAP RING
O-RING
GOVERNOR LEVER ASSEMBLY
TENSION LEVER
SNAP RING
WASHER
COTTER PIN
SPRING
SPRING
ARM
O-RING
SNAP RING
BRACKET
BOLT
BOLT
SCREW HHC M6-1.0 X 25
O-RING
O-RING
SPACER
GASKET
HOLDER (OIL FILL)
O-RING
CAP
BOLT
NUT
BRACKET, FUEL FILTER (MODEL 04270 & 04614)
SCREW HHC M8-1.25 X 60 G8.8 (MODEL 04270 & 04614)
SCREW HHC M8-1.25 X 65 G8.8 (MODEL 04270 & 04614)
NUT HEX M8-1.25 G8 (MODEL 04270 & 04614)
WASHER LOCK M8-5/16 (MODEL 04270 & 04614)
Page 85
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Engine Block Drawing No. 082961-C
24
23
22
25
18
28
17
15
20
13
19
12
14
14
33
30
29
1
14
31
2
ITEM
QTY.
1
2
3
1
20
1
12
1
1
13
14
15
5
1
Page 86
DESCRIPTION
OIL PAN
BOLT
O-RING (MODELS 04270 & 04614
ONLY)
DIPSTICK TUBE (ALL MODELS
EXCEPT 04270 & 04614)
DIPSTICK TUBE (MODELS 04270
& 04614 ONLY)
O-RING (ALL MODELS EXCEPT
04270 & 04614)
BOLT
DIPSTICK (ALL MODELS EXCEPT
04270 & 04614)
ITEM
QTY.
17
18
19
20
22
23
24
25
28
29
30
31
33
1
1
1
1
1
3
1
1
1
1
1
1
1
DESCRIPTION
ROCKER COVER GASKET
ROCKER COVER
OIL STOPPER
SCREEN
GASKET
NUT
CAP
O-RING
1/4" PIPE PLUG SQ. HD.
O-RING
TUBING
SUCTION FILTER
GASKET
Section 9
Exploded Views / Part Numbers
1.0 Liter Diesel Water Pump Drawing No. 082962
4
3
7
5
2
10
6
8
15
11
9
12
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
15
QTY.
1
1
1
1
3
1
1
1
1
1
1
1
1
DESCRIPTION
WATER PUMP ASSEMBLY
PLUG
THERMOSTAT
SPRING
GASKET
SET PLATE
BOLT
GASKET
BOLT
BOLT
NUT
PULLEY
BOLT
Page 87
Page 88
45
[1.77 "]
42 1 [16 .5 7 "]
3 7 1 [14 .6 1"]
63
[2 .4 8 "]
26
[1.02 "]
24
[.94 "]
F U E L RE T U R N
67 [22 .3 2 "]
ER SCREWS
53 6 .3
[2 1.12 "]
2 9.35
[1.16 "]
E X HA U S T O U TL E T
5 16 .5
H O U R M E T ER
COO L A N T F ILL
9 2 9 [3 6 .5 7 "]
OVER SCREWS
9 17 .5 [3 6 .12 "]
RE A R SERV ICE P A N E L
99
[3 .90"]
289
[11.3 8 "]
3 / 8 - 16 U N C M O U N TIN G H O L ES
[4 PL CS ]
B A TT ER Y CO NN EC TIO N
N E G A TIVE (- )
B A TT ER Y CO NN EC TIO N
P OS ITIVE (+ )
F U E L S U PPL Y
CE N
2 9 1.5
[11.4 8 "]
8 .5
00"]
1.0
[.03
4 19
[16 .50
A C P OWER HA R N ESS
[1/ 2 " LIQ U ID- TIG H T CO N D U IT]
E L EC T R IC A L A CCESS
.5
0 "]
M O T E CO NN EC TIO N K N OC K O U T
C IRC U IT B RE A K ER
P RE H E A T
F U SE (14 A M P )
S T O P / S T A R T SW ITC H
O IL DIP S TIC K
O IL F ILL
"]
13 7 .6
5 .42 "]
R A DIA T OR C A P
A CCESS COVER
LIF TIN G E Y E
A CCESS COVER
6 04 [2 3 .78 "]
OVER SCREWS
5 9 5 .0 [2 3 .4 3 "]
38
1.5 "]
4 53 .6
[17 .14 "]
Section 10
SPECIFICATIONS & CHARTS
Major Features and Dimensions Drawing No. 0D2650-A
Section 10
SPECIFICATIONS & CHARTS
ENGINE SPECIFICATIONS
Type of Engine
Cylinder Arrangement
Displacement
Bore
Stroke
Compression Ratio
Combustion Chamber Type
Rated Horsepower
Cylinder Block
Number of Main Bearings
Number of Teeth on Flywheel
Type of Governor
Fuel Filter
Oil Filter
Oil Pressure
Type of Cooling System
Cooling Method
Type of Cooling Fan
Cooling System Capacity
Air Cleaner
Starter
Recommended Battery
Maximum Cranking Current
Ground Polarity
ISM Diesel
3, in-line
58.2 in3. (954 cc)
2.95 in. (75 mm)
2.83 in. (72 mm)
23-to-1
Pre-Combustion
13 @ 1,950 rpm
Cast Iron
4
104
Mechanical, Fixed Speed
Full Flow Spin-On
Full Flow with Bypass Valve
29-71 psi
Pressurized, Closed Recovery
Liquid-cooled
Centrifugal Puller
1.4 U.S. gals (5.3 L)
Disposable Filter (Part # C4880)
12-volt DC Electric
70 Ah, 360 Cold-cranking Amps (Minimum ratings)
220 Amps
Negative
GENERATOR SPECIFICATIONS
Rated Maximum Continuous AC Output at ...
85 F (29 C) Ambient
100 F (38 C) Ambient
120 F (49 C) Ambient
Rated Voltage
Rated Maximum Continuous AC Current at ...
7,500 Watts
120 Volts
240 Volts
7,000 Watts
120 Volts
240 Volts
6,000 Watts
120 Volts
240 Volts
Phase
Rotor Speed at No Load
Number of Rotor Poles
Engine RPM
Rated AC Frequency
Battery Charge Voltage
Battery Charge Current
Weight
Length
Width
Height
*All units are reconnectable to 120-volt-only AC output.
62.5 Amps
31.2 Amps
58.3 Amps
29.2 Amps
50.0 Amps
25.0 Amps
Single
3,780 rpm
2
1,950
60 Hz
14 Volts DC
2 Amps (max)
486 Pounds (Dry)
36.6 inches (929 mm)
23.8 inches (604 mm)
22.3 inches (567 mm)
Page 89
Section 10
SPECIFICATIONS & CHARTS
QUIETPACT 75
MODEL
4270
Rotor resistance
15.25 ohms
159 ohms
184 ohms
1.24 ohms
.132 ohms
.153 ohms
TORQUE SPECIFICATIONS
Starter
Flywheel
16.2-19 ft-lbs.
Rotor Pulley
34.2-41.8 ft-lbs.
Stator Bolts
16.2-19.8 ft-lbs.
Tension Bolt
44.1-53.9 ft-lbs.
Pulley Tension
44.1-53.9 ft-lbs.
32.4-39.6 ft-lbs.
Injector Nozzles
Page 90
75 in-lbs.
58-61 ft-lbs.
NOTES
Page 91
D IOD E 600 V, 6A MP
FU SE 14A MP S FE
FU EL P U MP
FU EL SO LEN OID
E N G IN E G RO U N D
FR A M E S TU D
85
SM
16
14
14
14
FS
RE D
LOS
13
0
GND3
13
GND2
56
157
14
14
18
G LOW
85
150
44
13
18
17
P LU G S
SH EET
GND6
B H2
55
0
14
1 OF 2
22
15
14
150
CO MPA RT M ENT
ENGINE CONTROL
150
14
12
15
14
15
14
14
18
17
44
15
1
0
0
CB 2
17
18
B H 1A
33
22
162
17
18
14
2
CB 1
B H1
GND5
44
15
150
13
0
0
66
44
11
TS
44 A
11A
11
44
15
1
0
PA NEL
CONTROL
GND4
F1
SW 1
162
R2
14
A VR
DP E
T1 T2 T2 T3
BC R
C O NN 1
14
12
GND1
B R U SH W ITH RE D(4) LE A D
CLO S E S T TO B E A RING
G N D 4- TH R U B O LT (C O N TRO L P A N EL)
G N D 5- G RO U N D S TU D (N O N -SE A LED C O MP )
D2 F1 FP FS G N D 1G N D 2-
17
44
17
44
85
R1
150
15
CB 1 - C IRCU IT B RE A K ER 35A
CB 2 - C IRCU IT B RE A K ER 4A
150
150
22
33
14
B H 1A - BU LK H EA D C O NN EC TOR, P LU G (B LA CK )
B H 2 - BU LK H EA D C O NN EC TOR, RE C EP TA C LE (G R A Y)
55
15
1
11A
66
44
11
22
14
14
33
22
33
22
33
22
44
33
44 A
6
2
A C / M IS C
56
15
11A
BLACK
14
14
11
22
15
15
W IRE #'s
11
17
18
15
66
3
0
2
44 A
4
22
13
6
Page 92
11
150
1
11
22
4
6
44
11
4
77
66
11
0D2793-B
04270-1
CO MPA RT M ENT
10
F U NCTION
4
22
11
6
2
Section 11
ELECTRICAL DATA
Wiring Diagram Drawing No. 0D2793-B (1 of 2) Models 04270-1 & 04270-2 Single 120/240VAC Output
22
12-
D IODE 600 V, 6A M P
FU SE 14A M P SFE
FUEL PU M P
FUEL SOLENO ID
ENG INE GROUND
FR A M E STUD
4A
85
SM
16
14
14
14
FS
RED
LO S
TION
13
0
GND 3
13
GND 2
56
157
14
BH 2A
14
18
150
11
13
18
17
GLO W PLUG S
85
55
11
55
SH EET
GND 6
BH 2
R1
0
14
D1
COMPARTMENT
2 OF 2
22
18
11
15
14
150
EN GINE CONTRO L
150
14
44
11
22
33
15
14
15
14
14
15
1
18
17
11
CB 2
17
18
BH 1A
44
22
162
17
18
14
2
BH 1
GND 5
GND 4
PANE L
CONTRO L
33 A
11A
11
33
15
1
0
TS
J U MPER
150
13
0
0
66
33
11
F1
SW 1
162
R2
14
A VR
13
DPE
T1 T2 T2 T3
BCR
CONN 1
14
12
GND 1
- HOUR M ETER
- LO W O IL PRE SS URE SW ITCH
- PREHE
A T CON TA C TOR
- RE SISTOR, 1 ohm 25W
- RE SISTOR 20 ohm , 12W
- STA R T CON TA C TOR
HM
LO S
PHC
R1
R2
SC
B R USH W IT H RE D(4) L EA D
C L O S E S T TO B EAR IN G
D2
F1
FP
FS
GND
GND
A D CONNEC
A D CONNEC
A D CONNEC
BH 1A - BULK HE
BH 2 - BULK HE
BH 2A - BULK HE
150
150
17
11
17
11
66
44
11
22
14
56
15
CB 1
11A
AC / M IS C
14
14
44
22
44
22
44
22
33
44
B L AC K
150
15
CB 1A
33 A
6
2
W IRE # 's
14
14
11A
F U NCT ION
15
1
17
18
15
66
3
11
22
15
15
4
22
11
33 A
11
10
150
1
11
22
4
6
33
11
4
77
66
11
0D2793-B
04270-1
COMPARTMENT
V O L TA G E RE G U L ATOR
4
22
11
6
2
Section 11
ELECTRICAL DATA
Wiring Diagram Drawing No. 0D2793-B (2 of 2) Models 04270-1 & 04270-2 Dual 120VAC 35A Output
0
0
Page 93
22
Section 11
ELECTRICAL DATA
Schematic Drawing No. 0D2792-A Models 04270-1 & 04270-2
R ED
B LAC K
LEG EN D
SC
13
16
16
SM
GP
13
157
PHC
SW
13
B H1-1 0
157
B H1
-11
PHC
150
15
150
13
15
150
157
FP
B LK
B LK
15
F1
15
B H2
-8
157
B H1
-1 2
SW1
0
15
B H1- 9
18
17
-8
14
17
14
14
B H2
-11
HM
B H2
14
B H1- 6
14
14
B H1
-5
B H 2- 4
FS
15
R2
18
14
D2
B H2
-7
-9
17
14
-5
B H 2- 2
15
EN G IN E
18
12
14
W H IT E
RED
WIR E CO L OR
LE G E ND
BLUE
44
85
B CW
15
B H1
-1
*
0
-1 0
66
55
R1
77
56
4
0
R ED
B CR
R EM OT E START/
0
B H2
-1 2
SEE WIRIN G
D IAG RA M
FOR D ETAILS
44
33
22
11
DPE
6
22
CB2
SCHEMATIC
1.0L DIESEL
120V O N LY A .C . O U TP U T CO NN ECTIO N S
(2-CIRC U ITS, 35 A EACH )
162
SEN D P E
FA VR
A LTER N ATOR O U TP U T
LEA D S
DPE
F+
4
11 33
44
B H2
-1 2
1
44
11
11
22 44
11
33
CB1
CB1
C B 1A
11A
22 33
44 A
33 A
T1
T3
22 44
A .C . O U TP U T
04270-1
D2792-A
Page 94
11A
A .C . O U TP U T
C U STO ME R CO NN ECTIO N
T2 T2
120V
120V
35A
35A
17 14
B LK
TO EN G IN E
CO N TRO L
TER M . #5
15
SC
LOS
T3
240V
T1
T2 T2
120V
120V
18
Section 11
ELECTRICAL DATA
Schematic Drawing No. 0C4945-A Model 04270-0
R ED
B LAC K
LEG EN D
SC
13
16
16
SM
GP
13
157
PHC
SW
13
B H1-1 0
157
B H1
-11
PHC
150
15
150
13
15
150
157
FP
B LK
B LK
15
F1
15
B H2
-8
157
B H1
-1 2
SW1
15
STOP
B H1- 9
18
17
D1
18
14
17
14
0
B H1
-8
14
B H1- 7
14
18
14
HM
B H2
-1
14
B H1- 6
B H1
-5
B H 2- 4
R2
18
18
FS
15
D2
B H2
-9
B H2
14
B H 2- 2
15
17
14
14
9 3 4
10
CO N TRO L
18
0
B H1
-1
N EU TR A L
FU N C T ION
FUSED DC
C ONTROL
WI R E C OLOR
B CW
15
0
B H2
-6
66
55
77
B H2
-1 0
56
85
4
0
B CR
HWT
15
17 14
18
SC
LOS
0
0
SEE WIRIN G
D IAG RA M
FOR D ETAILS
44
33
22
11
STOP CO NN ECTIO N
22
A
6
CB2
SCHEMATIC
1.0L DIESEL
120V O N LY A .C . O U TP U T CO NN ECTIO N S
(2-CIRC U ITS, 35 A EACH )
TO EN G IN E
CO N TRO L
TER M . #5
SEN D P E
FA VR
A LTER N ATOR O U TP U T
LEA D S
D P E SEN
F+
4
4
1
44
11
11 33
44
B H2
-1 2
11
22 44
11
33
CB1
CB1
C B 1A
11A
22 33
1.0L RV
C4945-A
44 A
11A
33 A
T1
T3
22 44
A .C . O U TP U T
C U STO ME R CO NN ECTIO N
A .C . O U TP U T
C U STO ME R CO NN ECTIO N
T2 T2
120V
120V
35A
35A
T3
240V
T1
T2 T2
120V
120V
Page 95
D IO D E 600 V, 6A M P
D IO D E 600 V, 6A M P
FU SE 14A M P SFE
FU EL PU M P
FU EL SOL EN O ID
EN G IN E G R O U N D
- TER M IN A L STR IP
C U STO M ER C O NN EC TIO N
PH C
R1
R2
SC
SM
SW 1
TS
FP
HWT
SM
85
16
P R EH EA T C O N TA C TO R
R ESISTO R , 1 ohm 25W
R ESISTO R 20 ohm, 12W
STA R T C O N TA C TO R
STA R TER M O TO R
SW ITC H STA R T/ STO P
- H O U R M ETER
HM
14
14
FS
R ED
LOS
GND3
G N D1
G N D 3- G R O U N D (B EA R IN G C A RR IER )
G N D 4- TH R U B OL T (C O N TR OL P A N EL)
D1 D2 F1 FP FS G N D1-
B H 2A - B U LK H EA D C O NN EC TO R , P LUG (G R A Y)
CB 1 - C IR C U IT B R EA K ER 35A
CB 2 - C IR C U IT B R EA K ER 4A
13
GND2
56
157
14
B H 2A
18
85
G LO W P LUG S
44
13
18
17
150
14
18
B H 1 - B U LK H EA D C O NN EC TO R , R EC EP TA C LE (B LA C K )
B H 1A - B U LK H EA D C O NN EC TO R , P LUG (B LA C K )
17
44
17
44
GND6
B H2
55
44
LEG EN D
R1
14
0
85
D1
C O MPA R T M E N T
SHEET 1 OF 2
22
15
14
150
E NGIN E C O N T R O L
150
14
12
15
14
15
14
18
17
44
15
1
BC R
C O NN 1
14
18
B H 1A
14
33
22
162
17
18
14
2
B H1
CB 1
0
0
GND5
44
15
13
0
0
TS
44 A
11A
11
44
15
1
0
PA N E L
CONTROL
GND4
SW 2
F1
SW 1
162
0
15
66
77
A VR
DPE
T1 T2 T2 T3
11A
B R U SH W ITH R E D(4) L E A D
CL OSEST TO
B E A RING
150
150
22
33
44 A
85
44
33
66
44
11
6
2
11A
A C / M IS C
56
15
85
14
14
11
22
15
15
4
22
13
6
BLACK
14
14
33
22
33
22
33
22
66
44
11
22
33
55
150
15
150
1
11
22
4
6
44
11
77
66
11
C4946-A
C O MPA R T M E N T
V O L T A G E R E G U L A TO R
W IRE #'s
15
1
17
18
15
66
3
12
0
2
44 A
11
22
4
1
11
Page 96
7
F U NC T IO N
4
22
11
6
2
Section 11
ELECTRICAL DATA
Wiring Diagram Drawing No. 0C4946-A (1 of 2) Model 04270-0 Single 120/240VAC Output
22
C L OSEST TO
- FUE L PUMP
- FUE L SO LEN OID
NN ECTIO N
- ST A RT CO N TA CTOR
- ST A RTER MOTOR
FP
SM
85
16
14
14
FS
RED
LOS
13
0
GND3
13
GND2
56
157
14
B H 2A
14
18
150
11
13
18
17
G LO W P LU G S
85
55
GND6
B H2
R1
55
0
0
14
D1
C O MPAR T M E N T
SHEET 2 OF 2
22
18
11
15
14
150
E N GIN E C O N T R O L
150
14
44
11
22
33
15
14
CO NN1
14
15
14
14
15
1
18
17
11
B CR
17
18
B H 1A
44
22
162
17
18
14
2
12
GND1
SW 2 - PRE H EA T S W ITCH
TS - TERMI NA L STRIP
CUSTOMER CO
NN ECTIO N
SC
SM
G N D 6HWT HM
LOS PH C R1 -
G N D 2- FR A ME STUD
G N D 3- G ROU N D (B EA RIN G C A RRIER )
G N D 4- TH RU B O LT (CO N TRO L P AN EL)
FP
FS
B H 2A - B U LK H EA D CO NN ECTOR , P LU G (G R AY )
C B1 - CIRCUIT B RE A K ER 35A
B E AR IN G
LEG EN D
150
150
66
44
11
22
14
17
11
17
11
B H1
PAN E L
33 A
11A
TS
GND4
CONTROL
11
33
15
1
0
J U MP E R
150
13
0
0
66
33
11
F1
SW 1
162
R2
14
A VR
13
DPE
T1 T2 T2 T3
GND5
C B1
11A
AC / M IS C
33
44
B L AC K
14
14
44
22
44
22
44
22
C B1A
33 A
6
2
W IR E # 's
56
15
85
14
14
11A
F U NC T IO N
150
15
17
18
15
66
3
11
22
15
15
4
22
11
33 A
11
10
150
1
11
22
4
6
33
11
4
77
66
11
C4946-A
C O MPAR T M E N T
V O L T A G E R E G U L A TO R
4
22
11
6
2
Section 11
ELECTRICAL DATA
Wiring Diagram Drawing No. 0C4946-A (2 of 2) Models 04270-0 Dual 120VAC 35A Output
0
0
Page 97
22
15
11