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