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