Diagnostic Repair Manual | Guardian Technologies 4270 instruction

QUIETPACT® 75D

DIAGNOSTIC REPAIR MANUAL

RECREATIONAL VEHICLE GENERATOR

MODEL 4270

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Guardian Technologies 4270 manual Diagnostic Repair Manual

Contents

Diagnostic Repair Manual Replacement Parts Safety Table of Contents 57-59 Electromagnetic Fields MagnetismElectromagnetic Induction More Sophisticated AC Generator Simple AC Generator Generator Operating Diagram Generator AC Connection System Field BoostLine Breakers 120 VAC only Connection for 120/240 VAC Dual Voltage LIC Grit or Abrasive to Clean Slip Rings Rotor Assembly Brush Holder Battery Charge ComponentsExcitation Circuit Components General Adjustment Procedure Adjust POT LED162 Voltage Regulator Control Panel Components Control Panel Component Identification Effects of Dirt and Moisture Cleaning the GeneratorDrying the Generator Insulation Resistance Testers Stator Insulation Resistance Brushing and Vacuum CleaningCloth or Compressed AIR Stator SHORT-TO-GROUND Tests Megohmmeter Testing Rotor Insulation VOM MetersMeasuring AC Voltage Measuring DC Voltage Measuring Current Measuring AC FrequencyMeasuring Resistance Ohms LAW Electrical Units Operational Analysis IntroductionCircuit CONDITION- OFF Circuit CONDITION- PRE-HEAT Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Circuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdowns Engine Control Circuit Board Battery Checking Battery State of Charge Effects of TemperatureCharging a Battery Adding Water START/STOP Switch Preheat SwitchAMP Fuse Starter Contactor & Motor Fuel Injection Pump Engine GovernorFuel NOZZLES/INJECTORS Glow Plugs Adapter LOW OIL Pressure Switch LOW OIL Pressure Switch High Coolant Temperature SwitchEngine Protective Devices Overspeed Protection Troubleshooting Flowcharts Troubleshooting Flowcharts Problem 3 No Battery Charge Output Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Test 1- Check NO-LOAD Voltage Frequency Test 2 Check & Adjust Test 4- Fixed Excitation TEST/ROTOR AMP Draw Test 3- Test Excitation Circuit Breaker Re-connect Wire 11 and Wire 22 to the Voltage Regulator Test 5- Wire ContinuityTest 6- Check Field Boost Set a VOM to its Rx1 scale Model QP75D Test 7 Test Stator DPE Winding Test 9- Check Brush Leads Test 8- Check Sensing Leads / Power Windings159W 184W Tance Tests Procedure Test 11- Check Rotor AssemblyTest 10 Check Brushes & Slip Rings Test 12 Check Main Circuit Breaker Test 15 Check Battery Charge OutputTest 13- Check Load Voltage Frequency Test 14- Check Load Watts & Amperage Battery Charge Rectifier BCR is a full wave rectifier Test 16 Check Battery Charge RectifierShort to Ground Set a VOM to read battery voltage 12 VDC Test 19- Test PRE-HEAT SwitchTest 18 TRY Cranking the Engine Test 20- Check Fuel Pump Test 23- Check Power Supply to Circuit Board Test 22- Check Battery & CablesDisconnect the connector from the wires of the fuel pump Test 21- Check 14 AMP Fuse Not Activated Test 24 Check START-STOP Switch Test 27 Check Starter Motor Test 26- Test Starter ContactorConditions Affecting Starter Motor Performance Pinion Checking the PinionTools for Starter Performance Test Measuring Current Tachometer Testing Starter MotorTest Bracket Starter motor test bracket may be made as shown in Figure Test 30 Check Wire Test 29 Check Wire 14 Power SupplyIf Wire 18 checks GOOD, proceed to Problem 8 Section Test 28- Check Fuel Supply Test 33- Test Glow Plugs Test 32- Test Preheat ContactorTest 34- Test D1 Diode Remove the valve cover from engine Disconnect the battery Test 35- Check Valve AdjustmentTest 36- Fuel Injector Pump Adjust the regulated pressure on the gauge to 80 psi If fuel is noted, proceed to next step in flowchartDown Test / Compression Test Repeat Steps 1 through 8 on remaining cylinder Test 40- Test Water Temperature Switch Test 38 Check OIL Pressure SwitchTest 39- Check Circuit Board for Ground If continuity is measure, replace the switch Test 43 Check Wire 15 for Short to GroundComponents for Short to Ground Major Disassembly Belt Tensioning RE-ASSEMBLY FAN Belt Line Corner UP Between 5˚ to 10˚ Section Exploded Views / Part Numbers Stator Assembly Rotor AssemblyFlywheel Assembly Bearing Carrier, Front Base Frame Drawing No D2357-A Door, Service Front Door, Service RearBase Frame Weldment Slide Latch Flush Enclosure Drawing No D2358-D Cover, Access Electrical Cover, Access LiftGasket, Electrical Access Decal, Battery + Views / Part Cover Plate, Scroll Weldment 25 26 Assembly Marine Control Board Assembly, Potted RegulatorRectifier, Battery Charging Wire Assembly # Intake and Exhaust System Drawing No D2362-B Chamber Air Intake Exhaust GasketAir Filter Hose, Air Inlet Views / Part Numbers Boot, Battery Cable Fuel Pump AssemblyCable, Battery Wire Assembly, Black #4 Ground Customer Controls Assembly Drawing No D2364-D Switch, Pushbutton Spst Start / Stop SwitchBoot / Nut / Preheat Switch Boot, Circuit Breaker Camshaft Gear Camshaft AssemblyKEY Gear 2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B Spring Idler Gear AssemblyThrust Washer OIL Pump Cover Includes ALL Components Shown below Rocker ARM AssemblyIntake Rocker ARM Exhaust Rocker ARM Liter Diesel Injector Pump Drawing No -C Tank Return Model 04270 To Injection Pump To Fuel Pump 27 25 19 18 HOUSING, Timing Gear 3114 Liter Diesel Water Pump Drawing No Charts Generator Specifications Engine Specifications Type Quietpact Model ROTOR/STATOR Resistance ValuesPage Data Data Electrical Data C4945 Schematic Drawing No C4945-A Model C4946-A Electrical Sheet 2 OF4996 REV. 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