Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4270 manual Section Exploded Views / Part Numbers, Page

Models: 4270

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Customer Controls Assembly – Drawing No. 0D2364-D

Section 9

Exploded Views / Part Numbers

Customer Controls Assembly – Drawing No. 0D2364-D

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Guardian Technologies 4270 Section Exploded Views / Part Numbers, Customer Controls Assembly - Drawing No. 0D2364-D, Page

Contents

DIAGNOSTIC REPAIR MANUAL RECREATIONAL VEHICLE GENERATORQUIETPACT 75D MODELREPLACEMENT PARTS SAFETYNOTICE TO USERS OF THIS MANUAL TROUBLESHOOTING FLOWCHARTS Table of ContentsGENERATOR FUNDAMENTALS Table of Contents Check Rotor AssemblyCheck Battery Charge Output Check Battery Charge WindingsSection GENERATOR FUNDAMENTALS MAGNETISMELECTROMAGNETIC FIELDS ELECTROMAGNETIC INDUCTIONA SIMPLE AC GENERATOR A MORE SOPHISTICATED AC GENERATORFigure 1-5. - Alternating Current Sine Wave Figure 1-4. - A Simple AC GeneratorSection GENERATOR FUNDAMENTALS Figure 1-7. - Generator Operating DiagramGenerator operation may be described briefly as fol- lows FIELD BOOST GENERATOR AC CONNECTION SYSTEMGENERATOR CONVERSION TO 120 VAC ONLY - DUAL CIRCUITS Section GENERATOR FUNDAMENTALSFigure 1-8. - Connection for 120/240 VAC Dual Voltage Figure 1-9 - Connection for 120 VAC Only - Dual Circuits7. Remove the tie bar between the two-line breaker switch han- dles Section GENERATOR FUNDAMENTALSROTOR ASSEMBLY STATOR ASSEMBLYSection MAJOR GENERATOR COMPONENTS Figure 2-1. Exploded View of GeneratorBATTERY CHARGE COMPONENTS Figure 2-4. - Battery Charge CircuitFigure 2-5. - Schematic Excitation Circuit BRUSH HOLDERFigure 2-6. - Excitation Circuit Breaker Figure 2-7. - Voltage RegulatorSection MAJOR GENERATOR COMPONENTS VOLTAGE REGULATORCONTROL PANEL COMPONENT IDENTIFICATION Figure 2-9. - Control Panel ComponentsSection MAJOR GENERATOR COMPONENTS PageCLEANING THE GENERATOR Section INSULATION RESISTANCE TESTSEFFECTS OF DIRT AND MOISTURE DRYING THE GENERATORFigure 3-2. - Stator Leads STATOR INSULATION RESISTANCESection INSULATION RESISTANCE TESTS TESTING ROTOR INSULATION THE MEGOHMMETERFigure 3-3. - Rotor Test Points Section INSULATION RESISTANCE TESTSSection MEASURING ELECTRICITY METERSTHE VOM MEASURING AC VOLTAGEMEASURING AC FREQUENCY MEASURING CURRENTMEASURING RESISTANCE Figure 4-2. - Clamp-On AmmeterELECTRICAL UNITS OHMS LAWFigure 4-4. - Electrical Units 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 SYSTEMBATTERY ENGINE CONTROL CIRCUIT BOARDWIRE Section ENGINE DC CONTROL SYSTEMSection ENGINE DC CONTROL SYSTEMFigure 5-4 - Engine Control Circuit Board NOTE Water cannot be added to some “mainte- nance-free” batteriesPREHEAT SWITCH START/STOP SWITCHA. Schematic B. SchematicENGINE GOVERNOR FUEL INJECTION PUMPFUEL NOZZLES/INJECTORS GLOW PLUGSLOW OIL PRESSURE SWITCH HIGH COOLANT TEMPERATURE SWITCHFigure 5-13. - High Coolant Temperature Switch ENGINE PROTECTIVE DEVICESSection TROUBLESHOOTING FLOWCHARTS Problems 1 through 4 apply to the AC generator onlyINTRODUCTION PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS Problem 3 - No Battery Charge Outputcontinued PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageSection TROUBLESHOOTING FLOWCHARTS PageDIAGNOSTIC TESTS TEST 2 - CHECK & ADJUSTFigure 7-1. - Governor Adjustment Points TEST 1- CHECK NO-LOAD VOLTAGE AND FREQUENCYSection DIAGNOSTIC TESTS TEST 3- TEST EXCITATION CIRCUIT BREAKERTEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW Figure 7-2. - Excitation “DPE” Circuit BreakerTEST 5- WIRE CONTINUITY TEST 6- CHECK FIELD BOOSTSection DIAGNOSTIC TESTS TEST 4 RESULTSFigure 7-4. - Stator Excitation Winding TEST 7 - TEST STATOR DPE WINDINGSection DIAGNOSTIC TESTS TEST 8- CHECK SENSING LEADS / POWER WINDINGS Figure 7-5. - Stator Power Winding LeadsTEST 9- CHECK BRUSH LEADS Section DIAGNOSTIC TESTSTEST 11- CHECK ROTOR ASSEMBLY Figure 7-7. - Rotor AssemblyTEST 10 - CHECK BRUSHES & SLIP RINGS Figure 7-6. - Brush LeadsTEST 15 - CHECK BATTERY CHARGE OUTPUT TEST 12 - CHECK MAIN CIRCUIT BREAKERTEST 13- CHECK LOAD VOLTAGE FREQUENCY TEST 14- CHECK LOAD WATTS & AMPERAGETEST 16 - CHECK BATTERY CHARGE RECTIFIER TEST 17 - CHECK BATTERY CHARGE WINDINGS / BATTERY CHARGE RESISTORFigure 7-9. - Battery Charge Rectifier Section DIAGNOSTIC TESTSTEST 19- TEST PRE-HEAT SWITCH Pre-Heat SwitchTEST 18 - TRY CRANKING THE ENGINE TEST 20- CHECK FUEL PUMPTEST 22- CHECK BATTERY & CABLES TEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARDTEST 21- CHECK 14 AMP FUSE Figure 7-11. - 14 Amp FuseTEST 24 - CHECK START-STOP SWITCH Figure 7-12. - Start-Stop SwitchFigure 7-13. - Test 24, Step Section DIAGNOSTIC TESTSTEST 25 - CHECK POWER SUPPLY TO WIRE TEST 26- TEST STARTER CONTACTORTEST 27 - CHECK STARTER MOTOR Section DIAGNOSTIC TESTSFigure 7-15. - Check Starter Pinion Figure 7-14. - Starter Motor SMSection DIAGNOSTIC TESTS Figure 7-19. - Testing Starter Motor Performance Figure 7-16. - Clamp-On AmmeterFigure 7-17. - Tachometer Figure 7-18. - Test BracketTEST 29 - CHECK WIRE 14 POWER SUPPLY TEST 30 - CHECK WIREFigure 7-20. - Remote Harness Connector TEST 28- CHECK FUEL SUPPLYTEST 32- TEST PREHEAT CONTACTOR TEST 33- TEST GLOW PLUGSTEST 34- TEST D1 DIODE Section DIAGNOSTIC TESTSTEST 35- CHECK VALVE ADJUSTMENT Figure 7-22. - Valve Adjustment PointsFigure 7-23. - Checking Valve Adjustment TEST 36- FUEL INJECTOR PUMPTEST 37 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TESTSection DIAGNOSTIC TESTS TEST 38 - CHECK OIL PRESSURE SWITCH TEST 40- TEST WATER TEMPERATURE SWITCHFigure 7-23. - Oil Pressure Switch TEST 39- CHECK CIRCUIT BOARD FOR GROUNDTEST 43 - CHECK WIRE 15 FOR SHORT TO GROUND TEST 41- CHECK WIRE 14 AND CONNECTINGTEST 42 - CHECK WIRE 56 AND STARTER CONTACTOR FOR SHORT TO GROUND COMPONENTS FOR SHORT TO GROUNDSection ASSEMBLY MAJOR DISASSEMBLYFigure 8-2. - Using Prybar to Stabilize Flywheel Figure 8-1. - Block of Wood Under Rear of EngineRE-ASSEMBLY BELT TENSIONINGFigure 8-3. - Radiator Removal Points Figure 8-4. - Drive Belt TensionerFigure 8-5. - Applying Tension to Drive Belt Tensioner Figure 8-6. - Position of Drive Belt TensionerFigure 8-7. - Position of Fan Belt Tensioner Figure 8-8. - Leveling Fan Belt TensionerSection Exploded Views / Part Numbers 43 7Engine, Alternator Drive & Starter - Drawing No. 0D2355-B 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 RHViews / Part NumbersExploded 3034Exploded Views / Part Numbers Housing, Fan Scroll WeldmentFiller Neck Assembly, Radiator Remote SectionElectrical Enclosure Assembly - Drawing No. 0D2361-E Section Exploded Views / Part NumbersPage 28 1 27 29Exploded Views / Part Numbers SectionDESCRIPTION Section Exploded Views / Part Numbers Intake and Exhaust System - Drawing No. 0D2362-BPage TO ENGINE AIR INTAKESection Exploded Views / Part Numbers DESCRIPTIONViews / Part Numbers 1 2 12 2Section 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 No2630 CONNECTORSection Exploded Views / Part Numbers 1.0 Liter Diesel Cylinder Block - Drawing NoCYLINDER HEAD ASSEMBLY OIL SWITCHTHERMO-SWITCH Section Exploded Views / Part NumbersCRANKSHAFT ASSEMBLY BEARING HOLDER ASSEMBLYCONNECTING ROD 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 NumbersINJECTOR PUMP ASSEMBLY CONNECTORSection Exploded Views / Part Numbers 1.0 Liter Diesel Injector Pump - Drawing No. 075686-CTank Return Model 04270To Injection Pump To Fuel Pump27 25 19 18Section Exploded Views / Part Numbers 1.0 Liter Diesel Timing and Governor - Drawing No. 082067-BHOUSING, TIMING GEAR GOVERNOR LEVER ASSEMBLYSection Exploded Views / Part Numbers3114 Section Exploded Views / Part Numbers1.0 Liter Diesel Engine Block - Drawing No. 082961-C DESCRIPTIONWATER PUMP ASSEMBLY Section Exploded Views / Part Numbers1.0 Liter Diesel Water Pump - Drawing No PLUGCHARTS SPECIFICATIONSMajor Features and Dimensions - Drawing No. 0D2650-A SectionSPECIFICATIONS & CHARTS ENGINE SPECIFICATIONSGENERATOR SPECIFICATIONS DisplacementTORQUE SPECIFICATIONS Section SPECIFICATIONS & CHARTSROTOR/STATOR RESISTANCE VALUES Page DATA ELECTRICALSection PageSection 11 DATA WIRE DIAGRAM, 1.0L DSL120VAC 35A Output ELECTRICALSection ELECTRICAL DATA Schematic - Drawing No. 0D2792-A Models 04270-1SCHEMATIC 1.0L DIESEL PageSchematic - Drawing No. 0C4945-A Model Section ELECTRICAL DATAC4945 PageSection 11 ELECTRICAL Wiring DiagramWIRE DIAGRAM, 1.0L DSL PageWIRE DIAGRAM, 1.0L DSL SHEET 2 OFDUAL 120VAC, 35A OUTPUT Section 11 DATAP/N OF4996 REV. O PRINTED IN THE USA/1.05