Guardian 4270 manual

DIAGNOSTIC REP AIR MANUAL DIAGNOSTIC REP AIR MANUAL QUIETP ACT ® 75D RECREA TIONAL VEHICLE GENERA TOR MODEL 4270[...]

SAFETY Throughout this publication, "DANGER!" and "CAUTION!" blocks are used to alert the mechanic for special instructions concerning a particular service or operation that might be hazardous if performed incorrectly or carelessly. PAY CLOSE ATTENTION TO THEM. DANGER! UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCTIONS WHICH,[...]

T ab le of Contents Page 1 SAFETY ............................ INSIDE FRONT COVER SECTION 1: GENERATOR FUNDAMENTALS ...................... 3-7 MAGNETISM ................................................................ 3 ELECTROMAGNETIC FIELDS .................................... 3 ELECTROMAGNETIC INDUCTION .............................. 3 A SIMPLE [...]

TEST 10 - Check Brushes & Slip Rings ........................................ 42 TEST 11 - Check Rotor Assembly ............................................ 42-43 TEST 12 - Check Main Circuit Breaker .......................................... 43 TEST 13 - Check Load Voltage & Frequency ................................ 43 TEST 14 - Check Loa[...]

Section 1 GENERA T OR FUND AMENT ALS MA GNETISM Magnetism can be used to produce electricity and electricity can be used to produce magnetism. Much about magnetism cannot be explained by our present knowledge. However, there are certain pat- terns of behavior that are known. Application of these behavior patterns has led to the development of gen- [...]

Section 1 GENERA T OR FUND AMENT ALS A SIMPLE A C GENERA T OR Figure 1-4 shows a very simple AC Generator. The generator consists of a rotating magnetic field called a ROTOR and a stationary coil of wire called a STA- TOR. The ROTOR is a permanent magnet which con- sists of a SOUTH magnetic pole and a NORTH mag- netic pole. As the MOTOR turns, its [...]

Section 1 GENERA T OR FUND AMENT ALS NOTE: AC output frequency at 3720 rpm will be about 62-Hertz. The “No-Load” is set slightly high to prevent excessive rpm, frequency and voltage droop under heavy electrical loading. Generator operation may be described briefly as fol- lows: 1. Some “residual” magnetism is normally present in the rotor a[...]

Section 1 GENERA T OR FUND AMENT ALS FIELD BOOST When the engine is cranked during startup, the engine control circuit board Terminals 9, 10, and 11 (Wire 14) are energized with 12 VDC. Connected to a Wire 14 is a resistor (R2) and a diode (D2). Battery current flows through the 20 ohm 12-watt resistor and the field boost diode D2, the voltage is r[...]

Section 1 GENERA T OR FUND AMENT ALS Reroute stator lead 44 from the line side terminal of CB1 (renamed as CB1A in Figure 1-9) to the ground stud location previously occupied by stator lead Wire 33. 2. Move smaller gauge (#18 AWG) Wire labeled #44 (not shown), from the top of CB1A to the top of CB1. Renumber this Wire 11. 3. Reroute stator lead Wir[...]

Section 2 MAJOR GENERA T OR COMPONENTS RO T OR ASSEMBL Y The Rotor is sometimes called the “revolving field”, since it provides the magnetic field that induces a voltage into the stationary Stator windings. Slip rings on the Rotor shaft allow excitation current from the voltage regulator to be delivered to the Rotor wind- ings. The Rotor is dri[...]

Section 2 MAJOR GENERA T OR COMPONENTS 3. Two excitation winding output leads (No. 2 and 6). These leads deliver unregulated excitation current to the voltage regulator. 4. Three (3) battery charge output leads (No. 55, 66 and 77). Figure 2-2. – Stator Output Leads BRUSH HOLDER The brush holder is retained in the rear bearing carri- er by two M5 [...]

Section 2 MAJOR GENERA T OR COMPONENTS Figure 2-6. – Excitation Circuit Breaker VOLTAGE REGULATOR: Six (6) leads are connected to the voltage regulator as follows: • Two (2) SENSING leads deliver ACTUAL AC out- put voltage signals to the regulator. These are Wires No. 11 and 22. • Two (2) leads (4 and 1) deliver the regulated direct current t[...]

Section 2 MAJOR GENERA T OR COMPONENTS Page 11 CONTROL P ANEL COMPONENT IDENTIFICA TION Figure 2-9. – Control Panel Components[...]

Section 3 INSULA TION RESIST ANCE TESTS EFFECTS OF DIRT AND MOISTURE Moisture and dirt are harmful to the continued good operation of any generator set. If moisture is allowed to remain in contact with the Stator and Rotor windings, some of the moisture will be retained in voids and cracks of the winding insula- tion. This will result in a reduced [...]

Section 3 INSULA TION RESIST ANCE TESTS DANGER!: DO NOT ATTEMPT TO WORK WITH SOLVENTS IN ANY ENCLOSED AREA. PROVIDE ADEQUATE VENTILATION WHEN WORKING WITH SOLVENTS. WITHOUT ADE- QUATE VENTILATION, FIRE, EXPLOSION OR HEALTH HAZARDS MAY EXIST . WEAR EYE PROTECTION. WEAR RUBBER GLOVES TO PROTECT THE HANDS. CLOTH OR COMPRESSED AIR: For small parts or w[...]

Section 3 INSULA TION RESIST ANCE TESTS a. Across Wires No. 33 and 2. b. Across Wires No. 11 (POWER) and 66. c. Across Wires No. 33 and 66. d. Across Wires No. 2 and 66. If a breakdown in the insulation between isolated windings is indicated, clean and dry the Stator. Then, repeat the test. If the Stator fails the second test, replace the Stator as[...]

Section 4 MEASURING ELECTRICITY METERS Devices used to measure electrical properties are called meters. Meters are available that allow one to measure (a) AC voltage, (b) DC voltage, (c) AC fre- quency, and (d) resistance in ohms. The following apply: • To measure AC voltage, use an AC voltmeter. • To measure DC voltage, use a DC voltmeter. •[...]

Section 4 MEASURING ELECTRICITY MEASURING A C FREQUENCY The generator's AC output frequency is proportional to Rotor speed. Generators equipped with a 2-pole Rotor must operate at 3600 rpm to supply a frequen- cy of 60-Hertz. Correct engine and Rotor speed is maintained by an engine speed governor. For models rated 60-Hertz, the governor is ge[...]

Section 4 MEASURING ELECTRICITY ELECTRICAL UNITS AMPERE: The rate of electron flow in a circuit is represented by the AMPERE. The ampere is the number of electrons flowing past a given point at a given time. One AMPERE is equal to just slightly more than six thou- sand million billion electrons per second. With alternating current (AC), the electro[...]

Section 5 ENGINE DC CONTROL SYSTEM INTRODUCTION The engine DC control system includes all compo- nents necessary for the operation of the engine. Operation includes off, preheat, cranking/starting, running, shutdown, and fault shutdown. The system is shown schematically. OPERA TIONAL ANAL YSIS CIRCUIT CONDITION- OFF: Battery voltage is available to[...]

Section 5 ENGINE DC CONTROL SYSTEM Page 19 CIRCUIT CONDITION- PRE-HEAT: When the PRE-HEAT SWITCH (SW) or the REMOTE PANEL PRE-HEAT SWITCH is closed by the operator, battery voltage is delivered across the closed switch contacts to the PRE-HEAT CONTAC- TOR (PHC) via Wire 150. The PRE-HEAT CONTAC- TOR (PHC) is now energized. The normally open (PHC) c[...]

Section 5 ENGINE DC CONTROL SYSTEM Page 20 CIRCUIT CONDITION- CRANKING: When the START-STOP-SWITCH (SW1) or REMOTE PANEL START-STOP-SWITCH is held at "START" position, Wire 17 from the Engine Control circuit board is connected to Ground. Engine control circuit board action will then deliver battery voltage to a STARTER CONTACTOR (SC) via [...]

Section 5 ENGINE DC CONTROL SYSTEM Page 21 CIRCUIT CONDITION-RUNNING: With the FUEL PUMP (FP) and FUEL SOLENOID (FS) operating the engine should start. The START- STOP SWITCH (SW1) is then released. Engine con- trol circuit board action terminates DC output to the STARTER CONTACTOR (SC), which then de-ener- gizes the (SC) to end cranking. While run[...]

Section 5 ENGINE DC CONTROL SYSTEM Page 22 CIRCUIT CONDITION- SHUTDOWN: Setting the START-STOP SWITCH (SW1) or the REMOTE PANEL START-STOP SWITCH to its "STOP" position, connects the Wire 18 circuit to ground. ENGINE CONTROL circuit board action de- energizes DC output to Terminal 9,10, & 11 (Wire 14). The FUEL PUMP (FP), FUEL SOLENOI[...]

Section 5 ENGINE DC CONTROL SYSTEM Page 23 CIRCUIT CONDITION- FAULT SHUTDOWNS: The engine has mounted to it a HIGH WATER TEM- PERATURE SWITCH (HWT) and a LOW OIL PRES- SURE SWITCH (LOS). While running, ENGINE CONTROL circuit board action keeps Terminal 12 Wire 85 energized with battery voltage. Connected in parallel to (Wire 85) are the LOW OIL PRE[...]

Section 5 ENGINE DC CONTROL SYSTEM ENGINE CONTROL CIRCUIT BO ARD GENERAL: The ENGINE CONTROL circuit board is responsible for cranking, startup, running, and shutdown opera- tions. The board interconnects with other components of the DC control system to turn them on and off at the proper times. It is powered by fused 12 VDC power from the unit bat[...]

Section 5 ENGINE DC CONTROL SYSTEM battery and starter should not exceed 0.12 VDC per 100 amperes of cranking current. Select the battery cables based on total cable length and prevailing ambient temperature. Generally, the longer the cable and the colder the weather, the larg- er the required cable diameter. The following chart applies: CABLE LENG[...]

Section 5 ENGINE DC CONTROL SYSTEM 14 AMP FUSE This panel-mounted Fuse protects the DC control cir- cuit against overload and possible damage. If the Fuse has melted open due to an overload, neither the priming function nor the cranking function will be available. Figure5-4 PREHEA T SWITCH The diesel engine is equipped with glow plugs, one for each[...]

Section 5 ENGINE DC CONTROL SYSTEM The positive (+) battery cable (13) attaches to one of the outer posts of the contactor along with Wire 13 for the DC supply to the fuse (F1). The starter cable (16) attaches to the remaining outer post. Attached to the small 2 lugs are Wires 56 and 0. When the start/stop switch is set to start, the circuit board [...]

Section 5 ENGINE DC CONTROL SYSTEM Figure 5-11. – Glow Plug ENGINE PRO TECTIVE DEVICES The engine will shut down automatically in the event of anyone or more of the following occurrences: • Low oil • High engine coolant temperature • Engine overspeed LO W OIL PRESSURE SWITCH The oil pressure switch has normally-closed contacts. When the eng[...]

Section 6 TROUBLESHOO TING FLO WCHAR TS The “Flow Charts” in this section can be used in con- junction with the “Diagnostic Tests” of Section 7. Numbered tests in the Flow Charts correspond to identically numbered tests of Section 7. Problems 1 through 4 apply to the AC generator only. Beginning with Problem 5, the engine DC control sys- te[...]

Section 6 TROUBLESHOO TING FLO WCHAR TS Page 30[...]

Section 6 TROUBLESHOO TING FLO WCHAR TS Page 31 TEST 4 - PERFORM FIXED EXCIT A TION / RO T OR AMP DRA W TEST 7 - TEST ST A TOR DPE WINDING CHECK V OM FUSES - VERIFY AMP METER FUNCTIONS INSULA TION RESIST ANCE TEST P AGE 14 INSULA TION RESIST ANCE TEST P AGE 13 TEST 8 - CHECK SENSING LEADS / POWER WINDINGS TEST 11 - CHECK RO T OR ASSEMBL Y REP AIR O[...]

Section 6 TROUBLESHOO TING FLO WCHAR TS Page 32[...]

Section 6 TROUBLESHOO TING FLO WCHAR TS Page 33[...]

Section 6 TROUBLESHOO TING FLO WCHAR TS Page 34[...]

Section 6 TROUBLESHOO TING FLO WCHAR TS Page 35[...]

Section 6 TROUBLESHOO TING FLO WCHAR TS Page 36[...]

Section 7 DIA GNOSTIC TESTS Page 37 INTRODUCTION The “Diagnostic Tests” in this chapter may be per- formed in conjunction with the “Flow Charts” of Section 6. Test numbers in this chapter correspond to the numbered tests in the “Flow Charts”. Tests 1 through 17 are procedures involving problems with the generator's AC output voltag[...]

line voltage should read between 242-252 VAC. If voltage and frequency are good, no adjustment is needed. If voltage and frequency are low or high, proceed to next step. 4. Turn the governor adjusting screws to obtain a no-load frequen- cy as close as possible to 62-63 HERTZ. With no-load frequen- cy set, apply an electrical load as close as possib[...]

Section 7 DIA GNOSTIC TESTS Page 39 TEST 4 RESULTS ABCDE FG VOLTAGE RESULTS ABOVE ABOVE BELOW ZERO OR BELOW BELOW ABOVE WIRE 2 & 6 60 VAC 60 VAC 60 VAC RESIDUAL 60 VAC 60 VAC 60 VAC EXCITATION WINDING VOLTAGE (5-12 VAC) VOLTAGE RESULTS ABOVE BELOW ABOVE ZERO OR BELOW BELOW ABOVE WIRE 11 & 22 60 VAC 60 VAC 60 VAC RESIDUAL 60 VAC 60 VAC 60 VA[...]

3. Set the Start-Stop Switch to “START.” During cranking only, measure DC voltage. It should read 3-5 VDC. Reconnect Wire 4 to the Voltage Regulator. If voltage is measured, it can be assumed that the Field Boost is working. Stop testing. If volt- age is not measured, proceed to Step 4. 4. Test D2 diode: Place a VOM to measure continuity. Place[...]

Section 7 DIA GNOSTIC TESTS Page 41 TEST 8- CHECK SENSING LEADS / PO WER WINDINGS DISCUSSION: The Voltage Regulator “regulates” excitation current flow to the Rotor by electronically comparing sensing voltage to a pre-set reference voltage. The sensing voltage is delivered to the Voltage Regulator via Wires 11 and 22. If an open circuit exists [...]

one meter test lead to Wire 1. Connect the other test lead to a clean ground. The meter should read “Continuity”. RESULTS: 1. Repair, reconnect or replace any defective wire(s). 2. If wires check good, go to Test 10. Figure 7-6. – Brush Leads TEST 10 - CHECK BRUSHES & SLIP RINGS DISCUSSION: Brushes and slip rings are made of special mater[...]

Section 7 DIA GNOSTIC TESTS Page 43 RESULTS: 1. Replace the Rotor if it fails the test. 2. If Rotor checks good, perform “Insulation Resistance Test,” on Page 14. TEST 12 - CHECK MAIN CIRCUIT BREAKER DISCUSSION: The main circuit breaker on the generator panel must be closed or no output to the load will be available. A defective breaker may not[...]

approximately 0.8 Amps. Apply full load to the generator. The amp reading should increase to approximately 2 Amps. RESULTS: 1. If amperage was measured between 0.8 to 2 Amps in Step 2 and Step 3, the charging system is working. 2. If no amperage was measured, check the VOM fuses and veri- fy the functioning of the Amp Meter. If DC Amp Meter is good[...]

Section 7 DIA GNOSTIC TESTS Page 45 * Resistance values in ohms at 20° C. (68° F.). Actual readings may vary depending on ambient temperature. A tolerance of plus or minus 5% is allowed. RESULTS: 1. For Steps 2 & 3, keep in mind that the resistance values are very low. Depending upon the quality of the VOM, it may read “ Continuity” acros[...]

Section 7 DIA GNOSTIC TESTS Page 46 PROCEDURE: 1. Set a VOM to measure DC voltage. 2. Disconnect the connector from the wires of the fuel pump. 3. Place the positive (+) test lead on Wire 14 and the negative (-) test lead to clean ground. Press the pre-heat switch, battery voltage should be measured, if not, disconnect the other end of Wire 14. Pla[...]

3. Set the VOM to measure resistance (“Rx1” scale). Connect one meter test lead to Wire 0, Terminal 2 on the Engine Controller Circuit Board. Connect the other test lead to a clean frame ground. “ Continuity” should be measured. RESULTS: 1. If battery voltage is NOT indicated in Step 1, check continuity of: a . Wire 13 between Starter Conta[...]

Section 7 DIA GNOSTIC TESTS RESULTS: 1. If “Continuity” is not measured in Step 2, repair, reconnect or replace Wire 0 (between Start-Stop Switch and ground termi- nal) as necessary. 2. If engine cranks in Step 3 when Wire 17 is grounded, but will not crank when the Switch is set to “START”, replace the Start- Stop Switch. 3. If the Start-S[...]

Section 7 DIA GNOSTIC TESTS b. Open armature (wire broken) will be indicated by low or no RPM and excessive current draw. c. Grounded armature (wire insulation worn and wire touching armature lamination or shaft). Will be indicated by excessive current draw or no RPM. 3. A defective Starter Motor switch. 4. Broken, damaged or weak magnets. 5. Start[...]

Section 7 DIA GNOSTIC TESTS Figure 7-16. – Clamp-On Ammeter TACHOMETER: A tachometer is available from your Generac Power Systems source of supply. Order as P/N 042223. The tachometer measures from 800 to 50,000 RPM (see Figure 7-17). Figure 7-17. – Tachometer Figure 7-18. – Test Bracket TEST BRACKET: A starter motor test bracket may be made [...]

Section 7 DIA GNOSTIC TESTS TEST 28- CHECK FUEL SUPPL Y DISCUSSION: If the engine cranks but won't start, don't overlook the obvious. The fuel supply may be low. Many RV gen- erator installations "share" the fuel tank with the vehi- cles engine. When such is the case, the installer may have used a generator fuel pickup tube that[...]

Section 7 DIA GNOSTIC TESTS 6. Place test leads on each end of wire, continuity should be measured. 7. If continuity is measured, test battery voltage on Wire 14 going to circuit board on Pin 10, with prime switch pressed. Meter should read battery voltage. 8. Set a VOM to measure resistance. 9. Place a test lead on the terminal of the fuel solenoi[...]

Section 7 DIA GNOSTIC TESTS TEST 35- CHECK V AL VE ADJUSTMENT DISCUSSION: If the engine is having a hard start, no start, or rough running condition, then the valves will need to be checked for proper clearance. If a unit has a lot of hours on it, the valves will need to be readjusted. PROCEDURE: 1. Remove the valve cover from engine. 2. Disconnect[...]

Section 7 DIA GNOSTIC TESTS 8. Crank engine again and see if fuel is coming out of the fuel lines. RESULTS: 1. If no fuel is noted in Steps 3 or 8, replace fuel injector pump. (Reinstallation of all original shims will be required.) 2. If fuel is noted, proceed to next step in flowchart. TEST 37 - CHECK ENGINE / CYLINDER LEAK DO WN TEST / COMPRESSI[...]

Section 7 DIA GNOSTIC TESTS NOTE: For units out of warranty, refer to Quicksilver Diagnostic & Service Manual - Diesel, P/N 082034 for further engine service information. This manual can be found at www.guardiangener- ators.com, under “Brochures,Manual & Specs - Recreational Vehicle - Manuals”. TEST 38 - CHECK OIL PRESSURE SWITCH DISCUS[...]

Section 7 DIA GNOSTIC TESTS RESULTS: 1. If continuity is measure, replace the switch. 2. If infinity is measured, proceed to next test on the flow chart. TEST 41- CHECK WIRE 14 AND CONNECTING COMPONENTS FOR SHORT T O GROUND DISCUSSION: Once the start/stop switch is pressed, the circuit board will take battery voltage from Wire 15 on Pin 1 and provi[...]

Section 8 ASSEMBL Y MAJOR DISASSEMBL Y ENCLOSURE/ PANEL REMOVAL: Using a 10-mm socket, remove all screws on all pan- els except the lower screws on the radiator side panel. Remove the top panel first, then the side and rear. When removing the front panel, the main con- trol panel is mounted onto the front sheet metal. There are five nuts holding th[...]

Section 8 ASSEMBL Y 4. Attach a hoist hook to the top lifting bracket attached to the engine. 5. Slightly lift the engine to take pressure off of the block of wood. 6. Remove the bolts holding front cross member frame to the engine. STARTER REMOVAL: To get access to the starter for either testing or removal, the unit will need to be lifted in order[...]

Section 8 ASSEMBL Y Figure 8-5. – Applying Tension to Drive Belt Tensioner Figure 8-6. – Position of Drive Belt Tensioner FAN BELT: 1. Install fan belt tensioner as shown in Figure 8-7. Snug mount- ing bolt but do not tighten. 2. Using a small bubble level, verify that tensioner is level hori- zontally. If needed, tap the mounting bracket to le[...]

Section 9 Exploded Views / P art Numbers Page 60 26 4 6 45 42 41 22 2 5 1 40 38 3 7 36 21 17 26 26 23 3 25 49 2 28 13 44 49 50 4 11 28 7 29 19 3 1 10 9 14 18 24 3 2 25 27 33 35 21 22 2 0 21 39 21 43 39 Engine, Alternator Drive & Starter – Drawing No. 0D2355-B[...]

Section 9 Exploded Views / P art Numbers Page 61 ITEM QTY. DESCRIPTION 1 1 Bearing Carrier, Front 2 1 Bearing Carrier, Upper 3 1 Rotor Assembly 4 1 Stator Assembly 5 1 Ball Bearing 6 1 Ball Bearing 7 1 Brush Holder 8 2 Taptite M5-0.8 x 16mm 9 4 Bolt , Stator 10 6 5/16 Special Lock Washer 11 1 Lug, Lift 12 1 Rail, Engine RH 13 1 Pulley, 4.5" Fl[...]

Section 9 Exploded Views / P art Numbers Page 62 1 3 4 2 1 0 9 8 12 11 1 3 14 1 6 17 1 8 17 21 1 9 1 5 22 2 3 2 0 6 7 5 1 3 4 7 17 Base Frame – Drawing No. 0D2357-A[...]

Section 9 Exploded Views / P art Numbers Page 63 ITEM QTY. DESCRIPTION 1 1 Base Frame Weldment 2 1 Door, Service Rear 3 1 Door, Service Front 4 4 Slide Latch Flush 5 2 Vinyl Trim -Black 180mm 6 677mm Rubber Tape 1/8 x ½" 7 4 Grommet 1/8 x 13/32 8 4 Vibration Mount 9 1 Gasket, Cleanout 10 1 Plate, Cleanout 11 8 HHCS M8-1.25 x 16 12 8 Washer, S[...]

Section 9 Exploded Views / P art Numbers Page 64 38 36 37 17 24 17 1 5 35 14 34 21 17 26 VIEW " A" 1 8 17 6 4 17 31 32 11 2 8 30 1 0 A 22 17 1 9 2 9 33 27 17 1 3 20 12 17 1 6 8 5 23 2 17 2 5 7 3 17 1 9 2 Enclosure – Drawing No. 0D2358-D[...]

Section 9 Exploded Views / P art Numbers Page 65 ITEM QTY. DESCRIPTION 1 1 Enclosure Panel RH 2 1 Enclosure Panel Top 3 1 Enclosure Panel LH 4 1 Enclosure Panel Front 5 1 Enclosure Rear Panel 6 1 Insulation, Front Panel 7 1 Insulation, LH Side Panel 8 1 Insulation, RH Side Panel 9 1 Insulation, Top Front Panel 10 1 Insulation, Top Rear Panel 11 1 I[...]

Section 9 Exploded Views / P art Numbers Page 66 53 18 1 36 3 4 30 29 33 3 4 48 40 42 46 12 25 27 25 5 47 42 43 3 5 1 25 44 45 3 4 28 3 1 5 0 ( RE 3 7 38 23 5 4 5 21 19 3 4 3 2 41 4 41 2 49 14 39 21 18 14 4 17 20 39 15 5 8 6 14 13 11 55 26 22 10 3 7 1 9 Cooling System – Drawing No. 0D2360-B[...]

Section 9 Exploded Views / P art Numbers Page 67 ITEM QTY. DESCRIPTION 1 1 Cover Plate, Scroll Weldment 2 1 Housing, Fan Scroll Weldment 3 1 Fan, Squirrel Cage 4 1 Shaft, Fan 5 1 Carrier, Bearing 6 1 Key, Square 3/16" x 3/16" x ½" 7 1 Pulley, Fan 4-7/8" 8 1 Bearing 2 Row Ball 9 1 Fender Washer M16 10 1 Nut, Hex M16.0 -1.5mm 11 [...]

Section 9 Exploded Views / P art Numbers Page 68 19 17 16 5 14 11 15 28 27 25 26 6 1 2 2 20 1 4 7 25 2 6 27 28 13 2 8 8 18 3 3 3 2 27 29 31 11 Electrical Enclosure Assembly – Drawing No. 0D2361-E[...]

Section 9 Exploded Views / P art Numbers ITEM QTY. DESCRIPTION 1 1 Weldment, Electrical Enclosure 2 1 Terminal Block 4 Position 3 1 Assembly, Potted Regulator 4 1 Resistor 20R 5% 12W 5 1 Assembly Marine Control Board 6 1 Rectifier, Battery Charging 7 1 Circuit Breaker 5 Amp 8 A/R Tape, Glass Insulated 9 2 Taptite, M5-0.8 x 30 10 1 Taptite, M5-0.8 x[...]

Section 9 Exploded Views / P art Numbers Page 70 22 8 22 3 7 1 1 0 2 8 4 11 12 5 2 6 9 1 5 14 1 6 1 3 17 1 6 1 5 1 9 2 0 21 1 5 1 5 24 23 8 9 1 5 16 1 9 6 9 27 2 6 T O EN G INE AIR INTAK E 2 5 Intake and Exhaust System – Drawing No. 0D2362-B[...]

Section 9 Exploded Views / P art Numbers Page 71 ITEM QTY. DESCRIPTION 1 1 Exhaust Gasket 2 1 Chamber Air Intake 3 1 Air Filter 4 1 Hose, Air Inlet 5 1 Muffler Weldment 6 2 U Bolt & Saddle 1.25 7 1 Rail, Engine LH, Weldment 8 1 Insulation, Exhaust 9 3 Hose Clamp #28 10 1 Outlet, Exhaust Flex 11 1 Gasket, Exhaust Outlet 12 1 Plate, Exhaust Outle[...]

Page 72 Section 9 Exploded Views / P art Numbers 10 TO S TARTER M O T O R 16 26 TO G L O W PL UGS 1 7 17 16 10 8 25 13 17 4 26 12 4 19 20 MO T O R B O LT TO S TARTER 6 29 23 9 4 7 21 16 18 14 27 12 15 25 2 3 9 22 24 2 28 4 5 1 2 12 27 TO S TAT O R 7 11 TO G R OU ND 4 Fuel and Electrical Systems – Drawing No. 0D2363-C[...]

Page 73 Section 9 Exploded Views / P art Numbers ITEM QTY. DESCRIPTION 1 1 Fuel Pump Assembly 2 3 1/8 NPT x 5/16 Barbed Straight Fitting 3 2 Bulkhead Adaptor Fitting 4 7 Washer, Split Lk- ¼ -M6 5 1 HHCS M6-1.00 x 30 6 2 Relay Solenoid 7 5 Nut, Hex M6-1 8 1 Clamp, Vinyl Coat 1-1/16" 9 5 Washer, Flat -M6 10 2 Hose Clamp 11 1 1/8 NPT x 1/4 Barbe[...]

Page 74 Section 9 Exploded Views / P art Numbers 25 22 28 3 1 15 2 22 26 16 27 30 11 12 3 2 29 33 7 19 13 21 2 6 21 23 24 5 17 18 10 3 6 9 4 8 1 3 4 Customer Controls Assembly – Drawing No. 0D2364-D[...]

Page 75 Section 9 Exploded Views / P art Numbers ITEM QTY. DESCRIPTION 1 1 Start / Stop Switch 2 1 Cover, Engine Control Box 3 1 Hour Meter 4 1 Fuse Holder, SFE-14 5 1 Switch, Pushbutton SPST 6 2 PPHMS M3-0.5 x 10 7 2 Lockwasher M3 8 1 Fuse, SFE-14 9 1 Decal 10 1 Boot / Nut / Preheat Switch 11 4 Lockwasher, M5 12 1 Boot, Circuit Breaker 13 1 Harnes[...]

Page 76 Section 9 Exploded Views / P art Numbers 12 13 11 9 8 3 10 1 5 6 4 5 2 7 1.0 Liter Diesel Camshaft – Drawing No. 075677 ITEM QTY. DESCRIPTION 1 1 CAMSHAFT ASSEMBLY 2 1 CAMSHAFT GEAR 3 1 KEY 4 1 GEAR 5 3 SPACER 6 1 BALL BEARING 7 1 SLIDER 8 1 PLATE 9 1 TACHOMETER SHAFT 10 1 BOLT 11 1 BOLT 12 1 GASKET 13 1 NUT[...]

Page 77 Section 9 Exploded Views / P art Numbers 29 5 26 23 25 24 13 17 12 30 3 7 8 6 2 9 10 11 22 19 19 27 28 15 1 4 16 20 14 21 5 18 1.0 Liter Diesel Cylinder Block – Drawing No. 075676 ITEM QTY. DESCRIPTION 1 1 COMPLETE CYLINDER BLOCK 2 1 EXPANSION PLUG 3 1 EXPANSION PLUG 4 2 EXPANSION PLUG 5 2 EXPANSION PLUG 6 1 EXPANSION PLUG 7 4 PLUG 8 4 PL[...]

Page 78 Section 9 Exploded Views / P art Numbers 3 4 21 11 9 2 13 1 10 8 7 14 4 2 19 6 5 17 16 20 22 12 18 23 1.0 Liter Diesel Cylinder Head – Drawing No. 0D2794 ITEM QTY. DESCRIPTION 1 1 CYLINDER HEAD ASSEMBLY 2 6 EXPANSION PLUG 3 3 EXPANSION PLUG 4 2 XPANSION PLUG 5 3 INTAKE VALVE 6 3 EXHAUST VALVE 7 3 VALVE GUIDE SEAL (EXHAUST) 3 VALVE GUIDE S[...]

Page 79 Section 9 Exploded Views / P art Numbers 20 19 18 16 17 28 30 3 2 4 1 7 22 19 6 21 11 10 12 14 9 10 11 15 9 5 13 1.0 Liter Diesel Crankshaft, Piston and Flywheel – Drawing No. 075679-B ITEM QTY. DESCRIPTION 1 1 CRANKSHAFT ASSEMBLY 2 1 CRANKSHAFT GEAR 3 1 KEY 4 1 DOWEL PIN 5 1 SPRING PIN 6 1 BEARING HOLDER ASSEMBLY 7 1 BEARING HOLDER ASSEM[...]

Page 80 Section 9 Exploded Views / P art Numbers 5 12 3 2 4 8 6 7 9 1 11 10 1.0 Liter Diesel Oil Pump – Drawing No. 75682 ITEM QTY. DESCRIPTION 1 1 IDLER GEAR ASSEMBLY 2 1 SPRING 3 1 THRUST WASHER 4 1 ROTOR 5 1 OIL PUMP COVER 6 AR 0.10MM SHIM AR 0.15MM SHIM AR 0.20MM SHIM AR 0.50MM SHIM 7 1 SPRING 8 1 COLLAR 9 1 SNAP RING 10 1 FRONT PLATE 11 1 GA[...]

Page 81 Section 9 Exploded Views / P art Numbers 12 3 2 8 10 4 5 11 6 7 9 1.0 Liter Diesel Rocker Arm Assembly – Drawing No. 075683 ITEM QTY. DESCRIPTION 1 1 ROCKER ARM ASSEMBLY (INCLUDES ALL COMPONENTS SHOWN BELOW) 2 3 INTAKE ROCKER ARM 3 3 EXHAUST ROCKER ARM 4 6 NUT 5 6 STUD 6 3 ROCKER ARM BRACKET 7 1 ROCKER ARM SHAFT 8 2 SPRING 9 2 SCREW 10 3 [...]

Page 82 Section 9 Exploded Views / P art Numbers 11 4 14 13 12 1 2 16 & 04614 ONLY) (MODEL 04270 8 19 19 26 29 28 3 3 20 17 10 18 7 6 27 5 9 1.0 Liter Diesel Injector Pump – Drawing No. 075686-C ITEM QTY. DESCRIPTION 1 1 INJECTOR PUMP ASSEMBLY 2 AR SHIM-0.2MM AR SHIM-0.3MM AR SHIM-0.5MM AR SHIM-1.0MM 3 3 NUT 4 2 BOLT 5 3 GASKET 6 3 INSERT 7 3[...]

Page 83 Section 9 Exploded Views / P art Numbers To Injection Pump (Model 04270 & 04614) Tank (Return) 11 To Fuel 1 19 7 18 To Fuel Pump 2 5 3 6 5 18 16 15 16 16 13 14 17 10 14 17 4 5 14 9 10 6 8 1.0 Liter Diesel Fuel Supply – Drawing No. 075693-C ITEM QTY. DESCRIPTION 1 1 FUEL FILTER SUPPORT 2 1 FUEL FILTER 3 AR HOSE, 5/16" SAE 30R7 4 2[...]

Page 84 Section 9 Exploded Views / P art Numbers 3 45 44 47 43 42 4 40 49 50 48 42 36 37 1 35 38 13 25 29 30 27 33 32 31 26 28 34 4 5 2 6 1 23 24 22 (Model 04270 & 04614) 51 52 8 18 19 39 46 15 14 13 1 16 20 21 13 (Model 04270 & 04614) 1.0 Liter Diesel Timing and Governor – Drawing No. 082067-B[...]

Page 85 Section 9 Exploded Views / P art Numbers ITEM QTY. DESCRIPTION 1 1 HOUSING, TIMING GEAR 2 1 SPRING PIN 3 1 GASKET 4 1 SPRING 5 1 WASHER 6 2 NUT 7 1 STOP LEVER 8 2 COVER 11 1 GOVERNOR LEVER 12 1 BOLT 13 1 NUT 14 1 SHAFT 15 1 O-RING 16 1 SNAP RING 17 3 * BOLT 18 5 BOLT 19 1 OIL SEAL 20 4 BOLT 21 5 BOLT 22 1 ARM 23 1 SNAP RING 24 1 O-RING 25 1[...]

Page 86 Section 9 Exploded Views / P art Numbers 33 17 28 14 12 15 24 25 23 22 1 13 2 18 31 30 14 19 20 14 29 1.0 Liter Diesel Engine Block – Drawing No. 082961-C ITEM QTY. DESCRIPTION 1 1 OIL PAN 2 20 BOLT 3 1 O-RING (MODELS 04270 & 04614 ONLY) 12 1 DIPSTICK TUBE (ALL MODELS EXCEPT 04270 & 04614) 1 DIPSTICK TUBE (MODELS 04270 & 04614[...]

Page 87 12 11 9 6 5 8 7 4 1 2 3 15 10 1.0 Liter Diesel Water Pump – Drawing No. 082962 ITEM QTY. DESCRIPTION 1 1 WATER PUMP ASSEMBLY 2 1 PLUG 3 1 THERMOSTAT 4 1 SPRING 5 3 GASKET 6 1 SET PLATE 7 1 BOLT 8 1 GASKET 9 1 BOLT 10 1 BOLT 11 1 NUT 12 1 PULLEY 15 1 BOLT Section 9 Exploded Views / P art Numbers[...]

Section 10 SPECIFICA TIONS & CHARTS Page 88 24 [.9 4" ] 595. 0 [ 23. 43" ] 60 4 [ 23. 78 "] OVER SCREWS 91 7. 5 [ 3 6 . 12 " ] 1. 0 [. 03 929 [ 36. 57" ] OVER SCREWS O IL DIP S TIC K O IL F ILL STOP/START S W I T CH CI R C UI T BR E AKE R HOUR METE R FUS E ( 1 4 AMP) COO L A N T F ILL E L EC T R I C A L A CCESS L I FT I[...]

Section 10 SPECIFICA TIONS & CHARTS Page 89 Type of Engine ISM Diesel Cylinder Arrangement 3, in-line Displacement 58.2 in 3 . (954 cc) Bore 2.95 in. (75 mm) Stroke 2.83 in. (72 mm) Compression Ratio 23-to-1 Combustion Chamber Type Pre-Combustion Rated Horsepower 13 @ 1,950 rpm Cylinder Block Cast Iron Number of Main Bearings 4 Number of Teeth [...]

Section 10 SPECIFICA TIONS & CHARTS Page 90 T ORQUE SPECIFICA TIONS Starter 75 in-lbs. Flywheel 16.2-19 ft-lbs. Rotor Pulley 34.2-41.8 ft-lbs. Stator Bolts 16.2-19.8 ft-lbs. Tension Bolt 44.1-53.9 ft-lbs. Pulley Tension 44.1-53.9 ft-lbs. Weld Stud Nut 32.4-39.6 ft-lbs. Injector Nozzles 58-61 ft-lbs. RO T OR/ST A T OR RESIST ANCE V ALUES TYPE QU[...]

NO TES Page 91[...]

Section 11 ELECTRICAL D A T A Page 92 T1 22 15 15 14 4 6 4 T2 T2 T3 6 4 16 2 2 44 A 11 A 11 A 44 A 11 A 44 A 11 22 11 55 66 13 13 13 14 14 0 15 0 44 0 14 15 15 0 15 15 0 15 13 15 14 14 13 14 0 85 14 56 14 56 14 44 17 14 15 14 14 18 44 17 18 17 44 11 55 44 22 6 66 2 4 1 4 14 15 0 15 0 15 0 15 0 15 0 0 11 22 11 22 22 6 15 7 16 15 0 1 0 77 66 44 11 66[...]

Section 11 ELECTRICAL D A T A Page 93 14 16 14 0 14 0 56 15 0 0 13 0 0 0 15 7 0 56 15 0 13 15 0 14 14 17 11 85 14 22 18 11 15 14 11 0 0 1 17 11 18 1 1 15 0 0 1 0 15 0 13 0 17 18 0 22 66 22 44 55 4 1 11 55 2 6 11 4 14 15 14 44 22 14 66 15 44 22 14 15 0 15 44 22 16 2 16 2 11 0 2 18 17 17 14 18 22 14 0 44 T1 T2 11 A 6 6 22 4 1 11 T3 T2 33 A 0 15 14 14[...]

Page 94 Section 11 ELECTRICAL D A T A SW1 -SWITCH, START/STOP F1 - FU S E 14 A M P S FE D 1 - D IO D E 600V , 6 A M P B CW - B ATT E R Y CHAR G E R SC -START CO N TACTOR S -START ER LOS - LOW OI L PR E SS U R E SWITCH FP - FUE L P UM P C B 2 -CIRC U IT B R E A K E R ( 4 A ) LE G E N D S EE WIRI N G D IA G RA M FOR D E TAI LS R 2 -R E SISTOR, 2 0 OH[...]

Page 95 Section 11 ELECTRICAL D A T A SW1 -SWITCH, START/STOP F1 - FU S E 14 A M P S FE D 1 - D IO D E 600V , 6 A M P B CW - B ATT E R Y CHAR G E R SC -START CO N TACTOR S -START ER LOS - LOW OI L PR E SS U R E SWITCH FP - FUE L P UM P C B 2 -CIRC U IT B R E A K E R ( 4 A ) LE G E N D S EE WIRI N G D IA G RA M FOR D E TAI LS R 2 -R E SISTOR, 2 0 OH[...]

Page 96 Section 11 ELECTRICAL D A T A W IRE DIAGRAM , 1.0L DSL S IN G LE 12 0/ 24 0 VA C OU TP U T C 4 9 4 6 - A 6 7 1 2 12 11 7 HWT LOS G LO W P LUG S SW 2 D1 FP FS SW 1 CB 1 GND6 R1 GND 1 F1 GND4 GND5 BH 2 A BH 2 BH 1 A BH 1 SM BC R GND2 GND3 C O NN 1 AV R DPE 12 TS RE D 1 2V B AT TERY C O N N EC T I ON CU S T O ME R PR O V I DE D SHEET 1 OF 2 R1[...]

Page 97 Section 11 ELECTRICAL D A T A W IRE DIAGRAM , 1.0L DSL D UAL 120VAC , 35A OUTPUT C 4 9 4 6 - A 6 7 1 2 10 1 11 12 SHEET 2 OF 2 CUSTOMER PROVIDED 12V BA TTER Y CO NN ECTIO N SM FP GND1 RED FS LOS GL OW PL UGS GND2 BH 2 A GND6 BH 2 D1 GND3 R1 BC R CO NN1 GND5 R2 TS AV R DPE GND4 BH 1 A BH 1 F1 SW 1 CB 1 C B1A C O MPAR TMENT ENG I NE CONTROL C[...]

PO BOX 297 • WHITEWA TER, WI 53190 • www .guardiangenerators.com P/N OF4996 REV. O PRINTED IN THE USA/1.05[...]