Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4270 manual Section Exploded Views / Part Numbers, Page, 28 1 27 29

Models: 4270

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Electrical Enclosure Assembly – Drawing No. 0D2361-E

Section 9

Exploded Views / Part Numbers

Electrical Enclosure Assembly – Drawing No. 0D2361-E

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Guardian Technologies 4270 Section Exploded Views / Part Numbers, Electrical Enclosure Assembly - Drawing No. 0D2361-E

Contents

QUIETPACT 75D DIAGNOSTIC REPAIR MANUALRECREATIONAL VEHICLE GENERATOR MODELREPLACEMENT PARTS SAFETYNOTICE TO USERS OF THIS MANUAL TROUBLESHOOTING FLOWCHARTS Table of ContentsGENERATOR FUNDAMENTALS Check Battery Charge Output Table of ContentsCheck Rotor Assembly Check Battery Charge WindingsELECTROMAGNETIC FIELDS Section GENERATOR FUNDAMENTALSMAGNETISM ELECTROMAGNETIC INDUCTIONFigure 1-5. - Alternating Current Sine Wave A SIMPLE AC GENERATORA MORE SOPHISTICATED AC GENERATOR Figure 1-4. - A Simple AC GeneratorSection GENERATOR FUNDAMENTALS Figure 1-7. - Generator Operating DiagramGenerator operation may be described briefly as fol- lows GENERATOR CONVERSION TO 120 VAC ONLY - DUAL CIRCUITS FIELD BOOSTGENERATOR AC CONNECTION SYSTEM Section GENERATOR FUNDAMENTALS7. Remove the tie bar between the two-line breaker switch han- dles Figure 1-8. - Connection for 120/240 VAC Dual VoltageFigure 1-9 - Connection for 120 VAC Only - Dual Circuits Section GENERATOR FUNDAMENTALSSection MAJOR GENERATOR COMPONENTS ROTOR ASSEMBLYSTATOR ASSEMBLY Figure 2-1. Exploded View of GeneratorFigure 2-5. - Schematic Excitation Circuit BATTERY CHARGE COMPONENTSFigure 2-4. - Battery Charge Circuit BRUSH HOLDERSection MAJOR GENERATOR COMPONENTS Figure 2-6. - Excitation Circuit BreakerFigure 2-7. - Voltage Regulator VOLTAGE REGULATORSection MAJOR GENERATOR COMPONENTS CONTROL PANEL COMPONENT IDENTIFICATIONFigure 2-9. - Control Panel Components PageEFFECTS OF DIRT AND MOISTURE CLEANING THE GENERATORSection INSULATION RESISTANCE TESTS DRYING THE GENERATORFigure 3-2. - Stator Leads STATOR INSULATION RESISTANCESection INSULATION RESISTANCE TESTS Figure 3-3. - Rotor Test Points TESTING ROTOR INSULATIONTHE MEGOHMMETER Section INSULATION RESISTANCE TESTSTHE VOM Section MEASURING ELECTRICITYMETERS MEASURING AC VOLTAGEMEASURING RESISTANCE MEASURING AC FREQUENCYMEASURING CURRENT Figure 4-2. - Clamp-On AmmeterFigure 4-4. - Electrical Units ELECTRICAL UNITSOHMS LAW AMPERES = VOLTSOHMSINTRODUCTION Section ENGINE DC CONTROL SYSTEMOPERATIONAL ANALYSIS Section ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- PRE-HEATSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- CRANKINGSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION-RUNNINGSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- SHUTDOWNCIRCUIT CONDITION- FAULT SHUTDOWNS Section ENGINE DC CONTROL SYSTEMWIRE BATTERYENGINE CONTROL CIRCUIT BOARD Section ENGINE DC CONTROL SYSTEMFigure 5-4 - Engine Control Circuit Board SectionENGINE DC CONTROL SYSTEM NOTE Water cannot be added to some “mainte- nance-free” batteriesA. Schematic PREHEAT SWITCHSTART/STOP SWITCH B. SchematicFUEL NOZZLES/INJECTORS ENGINE GOVERNORFUEL INJECTION PUMP GLOW PLUGSFigure 5-13. - High Coolant Temperature Switch LOW OIL PRESSURE SWITCHHIGH COOLANT TEMPERATURE SWITCH ENGINE PROTECTIVE DEVICESINTRODUCTION Section TROUBLESHOOTING FLOWCHARTSProblems 1 through 4 apply to the AC generator only PageSection TROUBLESHOOTING FLOWCHARTS Pagecontinued Section TROUBLESHOOTING FLOWCHARTSProblem 3 - No Battery Charge Output PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageFigure 7-1. - Governor Adjustment Points DIAGNOSTIC TESTSTEST 2 - CHECK & ADJUST TEST 1- CHECK NO-LOAD VOLTAGE AND FREQUENCYTEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW Section DIAGNOSTIC TESTSTEST 3- TEST EXCITATION CIRCUIT BREAKER Figure 7-2. - Excitation “DPE” Circuit BreakerSection DIAGNOSTIC TESTS TEST 5- WIRE CONTINUITYTEST 6- CHECK FIELD BOOST TEST 4 RESULTSFigure 7-4. - Stator Excitation Winding TEST 7 - TEST STATOR DPE WINDINGSection DIAGNOSTIC TESTS TEST 9- CHECK BRUSH LEADS TEST 8- CHECK SENSING LEADS / POWER WINDINGSFigure 7-5. - Stator Power Winding Leads Section DIAGNOSTIC TESTSTEST 10 - CHECK BRUSHES & SLIP RINGS TEST 11- CHECK ROTOR ASSEMBLYFigure 7-7. - Rotor Assembly Figure 7-6. - Brush LeadsTEST 13- CHECK LOAD VOLTAGE FREQUENCY TEST 15 - CHECK BATTERY CHARGE OUTPUTTEST 12 - CHECK MAIN CIRCUIT BREAKER TEST 14- CHECK LOAD WATTS & AMPERAGEFigure 7-9. - Battery Charge Rectifier TEST 16 - CHECK BATTERY CHARGE RECTIFIERTEST 17 - CHECK BATTERY CHARGE WINDINGS / BATTERY CHARGE RESISTOR Section DIAGNOSTIC TESTSTEST 18 - TRY CRANKING THE ENGINE TEST 19- TEST PRE-HEAT SWITCHPre-Heat Switch TEST 20- CHECK FUEL PUMPTEST 21- CHECK 14 AMP FUSE TEST 22- CHECK BATTERY & CABLESTEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD Figure 7-11. - 14 Amp FuseFigure 7-13. - Test 24, Step TEST 24 - CHECK START-STOP SWITCHFigure 7-12. - Start-Stop Switch Section DIAGNOSTIC TESTSTEST 27 - CHECK STARTER MOTOR TEST 25 - CHECK POWER SUPPLY TO WIRETEST 26- TEST STARTER CONTACTOR Section DIAGNOSTIC TESTSFigure 7-15. - Check Starter Pinion Figure 7-14. - Starter Motor SMSection DIAGNOSTIC TESTS Figure 7-17. - Tachometer Figure 7-19. - Testing Starter Motor PerformanceFigure 7-16. - Clamp-On Ammeter Figure 7-18. - Test BracketFigure 7-20. - Remote Harness Connector TEST 29 - CHECK WIRE 14 POWER SUPPLYTEST 30 - CHECK WIRE TEST 28- CHECK FUEL SUPPLYTEST 34- TEST D1 DIODE TEST 32- TEST PREHEAT CONTACTORTEST 33- TEST GLOW PLUGS Section DIAGNOSTIC TESTSFigure 7-23. - Checking Valve Adjustment TEST 35- CHECK VALVE ADJUSTMENTFigure 7-22. - Valve Adjustment Points TEST 36- FUEL INJECTOR PUMPTEST 37 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TESTSection DIAGNOSTIC TESTS Figure 7-23. - Oil Pressure Switch TEST 38 - CHECK OIL PRESSURE SWITCHTEST 40- TEST WATER TEMPERATURE SWITCH TEST 39- CHECK CIRCUIT BOARD FOR GROUNDTEST 42 - CHECK WIRE 56 AND STARTER CONTACTOR FOR SHORT TO GROUND TEST 43 - CHECK WIRE 15 FOR SHORT TO GROUNDTEST 41- CHECK WIRE 14 AND CONNECTING COMPONENTS FOR SHORT TO GROUNDFigure 8-2. - Using Prybar to Stabilize Flywheel Section ASSEMBLYMAJOR DISASSEMBLY Figure 8-1. - Block of Wood Under Rear of EngineFigure 8-3. - Radiator Removal Points RE-ASSEMBLYBELT TENSIONING Figure 8-4. - Drive Belt TensionerFigure 8-7. - Position of Fan Belt Tensioner Figure 8-5. - Applying Tension to Drive Belt TensionerFigure 8-6. - Position of Drive Belt Tensioner Figure 8-8. - Leveling Fan Belt TensionerEngine, Alternator Drive & Starter - Drawing No. 0D2355-B Section Exploded Views / Part Numbers43 7 PageSection Exploded Views / Part Numbers DESCRIPTIONBase Frame - Drawing No. 0D2357-A Section Exploded Views / Part NumbersPage Section Exploded Views / Part Numbers DESCRIPTIONEnclosure - Drawing No. 0D2358-D Section Exploded Views / Part NumbersPage Section Exploded Views / Part Numbers Enclosure Panel RHExploded Views / PartNumbers 3034Filler Neck Assembly, Radiator Remote Exploded Views / Part NumbersHousing, Fan Scroll Weldment SectionPage Electrical Enclosure Assembly - Drawing No. 0D2361-ESection Exploded Views / Part Numbers 28 1 27 29Exploded Views / Part Numbers SectionDESCRIPTION Page Section Exploded Views / Part NumbersIntake and Exhaust System - Drawing No. 0D2362-B TO ENGINE AIR INTAKESection Exploded Views / Part Numbers DESCRIPTIONSection Views / Part Numbers1 2 12 2 ExplodedExploded Views / Part Numbers SectionDESCRIPTION Section Exploded Views / Part Numbers Customer Controls Assembly - Drawing No. 0D2364-DPage Exploded Views / Part Numbers SectionDESCRIPTION Section Exploded Views / Part Numbers 1.0 Liter Diesel Camshaft - Drawing NoSection Exploded Views / Part Numbers 2630CONNECTOR 1.0 Liter Diesel Cylinder Block - Drawing NoTHERMO-SWITCH CYLINDER HEAD ASSEMBLYOIL SWITCH Section Exploded Views / Part NumbersCONNECTING ROD ASSEMBLY CRANKSHAFT ASSEMBLYBEARING HOLDER ASSEMBLY BEARING HOLDER ASSEMBLYSection Exploded Views / Part Numbers 1.0 Liter Diesel Oil Pump - Drawing No1.0 Liter Diesel Rocker Arm Assembly - Drawing No Section Exploded Views / Part NumbersSection Exploded Views / Part Numbers INJECTOR PUMP ASSEMBLYCONNECTOR 1.0 Liter Diesel Injector Pump - Drawing No. 075686-CTo Injection Pump Tank ReturnModel 04270 To Fuel PumpSection Exploded Views / Part Numbers 27 2519 18 1.0 Liter Diesel Timing and Governor - Drawing No. 082067-BSection HOUSING, TIMING GEARGOVERNOR LEVER ASSEMBLY Exploded Views / Part Numbers1.0 Liter Diesel Engine Block - Drawing No. 082961-C 3114Section Exploded Views / Part Numbers DESCRIPTION1.0 Liter Diesel Water Pump - Drawing No WATER PUMP ASSEMBLYSection Exploded Views / Part Numbers PLUGMajor Features and Dimensions - Drawing No. 0D2650-A CHARTSSPECIFICATIONS SectionGENERATOR SPECIFICATIONS SPECIFICATIONS & CHARTSENGINE SPECIFICATIONS DisplacementTORQUE SPECIFICATIONS Section SPECIFICATIONS & CHARTSROTOR/STATOR RESISTANCE VALUES Page Section DATAELECTRICAL Page120VAC 35A Output Section 11 DATAWIRE DIAGRAM, 1.0L DSL ELECTRICALSCHEMATIC 1.0L DIESEL Section ELECTRICAL DATASchematic - Drawing No. 0D2792-A Models 04270-1 PageC4945 Schematic - Drawing No. 0C4945-A ModelSection ELECTRICAL DATA PageWIRE DIAGRAM, 1.0L DSL Section 11 ELECTRICALWiring Diagram PageDUAL 120VAC, 35A OUTPUT WIRE DIAGRAM, 1.0L DSLSHEET 2 OF Section 11 DATAP/N OF4996 REV. O PRINTED IN THE USA/1.05