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Guardian Technologies
4270 Control Panel Component Identification, 9. - Control Panel Components
Models:
4270
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Troubleshooting
Specs
7. - Generator Operating Diagram
Replacement Parts
Wire
Problem 3 - No Battery Charge Output
Diagnostic Repair Manual
Rotor Assembly
Circuit Condition- Fault Shutdowns
TEST 2 - CHECK & ADJUST
Page 13
Image 13
Section 2
MAJOR GENERATOR COMPONENTS
CONTROL PANEL COMPONENT IDENTIFICATION
Figure
2-9.
– Control Panel Components
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Page 12
Page 14
Page 13
Image 13
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Contents
RECREATIONAL VEHICLE GENERATOR
DIAGNOSTIC REPAIR MANUAL
QUIETPACT 75D
MODEL
REPLACEMENT PARTS
SAFETY
NOTICE TO USERS OF THIS MANUAL
TROUBLESHOOTING FLOWCHARTS
Table of Contents
GENERATOR FUNDAMENTALS
Check Rotor Assembly
Table of Contents
Check Battery Charge Output
Check Battery Charge Windings
MAGNETISM
Section GENERATOR FUNDAMENTALS
ELECTROMAGNETIC FIELDS
ELECTROMAGNETIC INDUCTION
A MORE SOPHISTICATED AC GENERATOR
A SIMPLE AC GENERATOR
Figure 1-5. - Alternating Current Sine Wave
Figure 1-4. - A Simple AC Generator
Section GENERATOR FUNDAMENTALS
Figure 1-7. - Generator Operating Diagram
Generator operation may be described briefly as fol- lows
GENERATOR AC CONNECTION SYSTEM
FIELD BOOST
GENERATOR CONVERSION TO 120 VAC ONLY - DUAL CIRCUITS
Section GENERATOR FUNDAMENTALS
Figure 1-9 - Connection for 120 VAC Only - Dual Circuits
Figure 1-8. - Connection for 120/240 VAC Dual Voltage
7. Remove the tie bar between the two-line breaker switch han- dles
Section GENERATOR FUNDAMENTALS
STATOR ASSEMBLY
ROTOR ASSEMBLY
Section MAJOR GENERATOR COMPONENTS
Figure 2-1. Exploded View of Generator
Figure 2-4. - Battery Charge Circuit
BATTERY CHARGE COMPONENTS
Figure 2-5. - Schematic Excitation Circuit
BRUSH HOLDER
Figure 2-7. - Voltage Regulator
Figure 2-6. - Excitation Circuit Breaker
Section MAJOR GENERATOR COMPONENTS
VOLTAGE REGULATOR
Figure 2-9. - Control Panel Components
CONTROL PANEL COMPONENT IDENTIFICATION
Section MAJOR GENERATOR COMPONENTS
Page
Section INSULATION RESISTANCE TESTS
CLEANING THE GENERATOR
EFFECTS OF DIRT AND MOISTURE
DRYING THE GENERATOR
Figure 3-2. - Stator Leads
STATOR INSULATION RESISTANCE
Section INSULATION RESISTANCE TESTS
THE MEGOHMMETER
TESTING ROTOR INSULATION
Figure 3-3. - Rotor Test Points
Section INSULATION RESISTANCE TESTS
METERS
Section MEASURING ELECTRICITY
THE VOM
MEASURING AC VOLTAGE
MEASURING CURRENT
MEASURING AC FREQUENCY
MEASURING RESISTANCE
Figure 4-2. - Clamp-On Ammeter
OHMS LAW
ELECTRICAL UNITS
Figure 4-4. - Electrical Units
AMPERES = VOLTSOHMS
INTRODUCTION
Section ENGINE DC CONTROL SYSTEM
OPERATIONAL ANALYSIS
CIRCUIT CONDITION- PRE-HEAT
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- CRANKING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION-RUNNING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- SHUTDOWN
Section ENGINE DC CONTROL SYSTEM
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION- FAULT SHUTDOWNS
ENGINE CONTROL CIRCUIT BOARD
BATTERY
WIRE
Section ENGINE DC CONTROL SYSTEM
ENGINE DC CONTROL SYSTEM
Section
Figure 5-4 - Engine Control Circuit Board
NOTE Water cannot be added to some “mainte- nance-free” batteries
START/STOP SWITCH
PREHEAT SWITCH
A. Schematic
B. Schematic
FUEL INJECTION PUMP
ENGINE GOVERNOR
FUEL NOZZLES/INJECTORS
GLOW PLUGS
HIGH COOLANT TEMPERATURE SWITCH
LOW OIL PRESSURE SWITCH
Figure 5-13. - High Coolant Temperature Switch
ENGINE PROTECTIVE DEVICES
Problems 1 through 4 apply to the AC generator only
Section TROUBLESHOOTING FLOWCHARTS
INTRODUCTION
Page
Page
Section TROUBLESHOOTING FLOWCHARTS
Problem 3 - No Battery Charge Output
Section TROUBLESHOOTING FLOWCHARTS
continued
Page
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
Page
Section TROUBLESHOOTING FLOWCHARTS
TEST 2 - CHECK & ADJUST
DIAGNOSTIC TESTS
Figure 7-1. - Governor Adjustment Points
TEST 1- CHECK NO-LOAD VOLTAGE AND FREQUENCY
TEST 3- TEST EXCITATION CIRCUIT BREAKER
Section DIAGNOSTIC TESTS
TEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW
Figure 7-2. - Excitation “DPE” Circuit Breaker
TEST 6- CHECK FIELD BOOST
TEST 5- WIRE CONTINUITY
Section DIAGNOSTIC TESTS
TEST 4 RESULTS
Figure 7-4. - Stator Excitation Winding
TEST 7 - TEST STATOR DPE WINDING
Section DIAGNOSTIC TESTS
Figure 7-5. - Stator Power Winding Leads
TEST 8- CHECK SENSING LEADS / POWER WINDINGS
TEST 9- CHECK BRUSH LEADS
Section DIAGNOSTIC TESTS
Figure 7-7. - Rotor Assembly
TEST 11- CHECK ROTOR ASSEMBLY
TEST 10 - CHECK BRUSHES & SLIP RINGS
Figure 7-6. - Brush Leads
TEST 12 - CHECK MAIN CIRCUIT BREAKER
TEST 15 - CHECK BATTERY CHARGE OUTPUT
TEST 13- CHECK LOAD VOLTAGE FREQUENCY
TEST 14- CHECK LOAD WATTS & AMPERAGE
TEST 17 - CHECK BATTERY CHARGE WINDINGS / BATTERY CHARGE RESISTOR
TEST 16 - CHECK BATTERY CHARGE RECTIFIER
Figure 7-9. - Battery Charge Rectifier
Section DIAGNOSTIC TESTS
Pre-Heat Switch
TEST 19- TEST PRE-HEAT SWITCH
TEST 18 - TRY CRANKING THE ENGINE
TEST 20- CHECK FUEL PUMP
TEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD
TEST 22- CHECK BATTERY & CABLES
TEST 21- CHECK 14 AMP FUSE
Figure 7-11. - 14 Amp Fuse
Figure 7-12. - Start-Stop Switch
TEST 24 - CHECK START-STOP SWITCH
Figure 7-13. - Test 24, Step
Section DIAGNOSTIC TESTS
TEST 26- TEST STARTER CONTACTOR
TEST 25 - CHECK POWER SUPPLY TO WIRE
TEST 27 - CHECK STARTER MOTOR
Section DIAGNOSTIC TESTS
Figure 7-15. - Check Starter Pinion
Figure 7-14. - Starter Motor SM
Section DIAGNOSTIC TESTS
Figure 7-16. - Clamp-On Ammeter
Figure 7-19. - Testing Starter Motor Performance
Figure 7-17. - Tachometer
Figure 7-18. - Test Bracket
TEST 30 - CHECK WIRE
TEST 29 - CHECK WIRE 14 POWER SUPPLY
Figure 7-20. - Remote Harness Connector
TEST 28- CHECK FUEL SUPPLY
TEST 33- TEST GLOW PLUGS
TEST 32- TEST PREHEAT CONTACTOR
TEST 34- TEST D1 DIODE
Section DIAGNOSTIC TESTS
Figure 7-22. - Valve Adjustment Points
TEST 35- CHECK VALVE ADJUSTMENT
Figure 7-23. - Checking Valve Adjustment
TEST 36- FUEL INJECTOR PUMP
TEST 37 - CHECK ENGINE / CYLINDER LEAK
DOWN TEST / COMPRESSION TEST
Section DIAGNOSTIC TESTS
TEST 40- TEST WATER TEMPERATURE SWITCH
TEST 38 - CHECK OIL PRESSURE SWITCH
Figure 7-23. - Oil Pressure Switch
TEST 39- CHECK CIRCUIT BOARD FOR GROUND
TEST 41- CHECK WIRE 14 AND CONNECTING
TEST 43 - CHECK WIRE 15 FOR SHORT TO GROUND
TEST 42 - CHECK WIRE 56 AND STARTER CONTACTOR FOR SHORT TO GROUND
COMPONENTS FOR SHORT TO GROUND
MAJOR DISASSEMBLY
Section ASSEMBLY
Figure 8-2. - Using Prybar to Stabilize Flywheel
Figure 8-1. - Block of Wood Under Rear of Engine
BELT TENSIONING
RE-ASSEMBLY
Figure 8-3. - Radiator Removal Points
Figure 8-4. - Drive Belt Tensioner
Figure 8-6. - Position of Drive Belt Tensioner
Figure 8-5. - Applying Tension to Drive Belt Tensioner
Figure 8-7. - Position of Fan Belt Tensioner
Figure 8-8. - Leveling Fan Belt Tensioner
43 7
Section Exploded Views / Part Numbers
Engine, Alternator Drive & Starter - Drawing No. 0D2355-B
Page
DESCRIPTION
Section Exploded Views / Part Numbers
Base Frame - Drawing No. 0D2357-A
Section Exploded Views / Part Numbers
Page
DESCRIPTION
Section Exploded Views / Part Numbers
Enclosure - Drawing No. 0D2358-D
Section Exploded Views / Part Numbers
Page
Enclosure Panel RH
Section Exploded Views / Part Numbers
Numbers
Views / Part
Exploded
3034
Housing, Fan Scroll Weldment
Exploded Views / Part Numbers
Filler Neck Assembly, Radiator Remote
Section
Section Exploded Views / Part Numbers
Electrical Enclosure Assembly - Drawing No. 0D2361-E
Page
28 1 27 29
Exploded Views / Part Numbers
Section
DESCRIPTION
Intake and Exhaust System - Drawing No. 0D2362-B
Section Exploded Views / Part Numbers
Page
TO ENGINE AIR INTAKE
DESCRIPTION
Section Exploded Views / Part Numbers
1 2 12 2
Views / Part Numbers
Section
Exploded
Exploded Views / Part Numbers
Section
DESCRIPTION
Section Exploded Views / Part Numbers
Customer Controls Assembly - Drawing No. 0D2364-D
Page
Exploded Views / Part Numbers
Section
DESCRIPTION
1.0 Liter Diesel Camshaft - Drawing No
Section Exploded Views / Part Numbers
CONNECTOR
2630
Section Exploded Views / Part Numbers
1.0 Liter Diesel Cylinder Block - Drawing No
OIL SWITCH
CYLINDER HEAD ASSEMBLY
THERMO-SWITCH
Section Exploded Views / Part Numbers
BEARING HOLDER ASSEMBLY
CRANKSHAFT ASSEMBLY
CONNECTING ROD ASSEMBLY
BEARING HOLDER ASSEMBLY
1.0 Liter Diesel Oil Pump - Drawing No
Section Exploded Views / Part Numbers
Section Exploded Views / Part Numbers
1.0 Liter Diesel Rocker Arm Assembly - Drawing No
CONNECTOR
INJECTOR PUMP ASSEMBLY
Section Exploded Views / Part Numbers
1.0 Liter Diesel Injector Pump - Drawing No. 075686-C
Model 04270
Tank Return
To Injection Pump
To Fuel Pump
19 18
27 25
Section Exploded Views / Part Numbers
1.0 Liter Diesel Timing and Governor - Drawing No. 082067-B
GOVERNOR LEVER ASSEMBLY
HOUSING, TIMING GEAR
Section
Exploded Views / Part Numbers
Section Exploded Views / Part Numbers
3114
1.0 Liter Diesel Engine Block - Drawing No. 082961-C
DESCRIPTION
Section Exploded Views / Part Numbers
WATER PUMP ASSEMBLY
1.0 Liter Diesel Water Pump - Drawing No
PLUG
SPECIFICATIONS
CHARTS
Major Features and Dimensions - Drawing No. 0D2650-A
Section
ENGINE SPECIFICATIONS
SPECIFICATIONS & CHARTS
GENERATOR SPECIFICATIONS
Displacement
TORQUE SPECIFICATIONS
Section SPECIFICATIONS & CHARTS
ROTOR/STATOR RESISTANCE VALUES
Page
ELECTRICAL
DATA
Section
Page
WIRE DIAGRAM, 1.0L DSL
Section 11 DATA
120VAC 35A Output
ELECTRICAL
Schematic - Drawing No. 0D2792-A Models 04270-1
Section ELECTRICAL DATA
SCHEMATIC 1.0L DIESEL
Page
Section ELECTRICAL DATA
Schematic - Drawing No. 0C4945-A Model
C4945
Page
Wiring Diagram
Section 11 ELECTRICAL
WIRE DIAGRAM, 1.0L DSL
Page
SHEET 2 OF
WIRE DIAGRAM, 1.0L DSL
DUAL 120VAC, 35A OUTPUT
Section 11 DATA
PRINTED IN THE USA/1.05
P/N OF4996 REV. O
