Guardian Technologies 4582 & 4987, 4583, 5308 Test 39 Check Carburetion, Test 40 Valve Adjustment

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Section 6

DIAGNOSTIC TESTS

PROCEDURE:

1.Remove the fuel line from the fuel filter on the inlet side of the carburetor. Use a suitable catch can to catch fuel.

2.Crank the engine over, fuel should flow from the fuel line. If fuel does not flow, verify that fuel is available to the pump. If fuel is available to the pump inspect the fuel filter, pulse line, and or replace the fuel pump.

RESULTS:

Refer to flow chart.

Test 39 - Check Carburetion

PROCEDURE:

Before making a carburetion check, be sure the fuel sup- ply tank has an ample supply of fresh, clean gasoline.

Check that all shutoff valves are open and fuel flows freely through the fuel line.

Make sure the choke operates properly.

If the engine will not start, remove and inspect the spark plug. If the spark plug is wet, look for the following:

•Overchoking.

•Excessively rich fuel mixture.

•Water in fuel.

•Intake valve stuck open.

•Needle/float stuck open.

If the spark plug is dry look for the following:

•Leaking carburetor mounting gaskets.

•Intake valve stuck closed.

•Inoperative fuel pump.

•Plugged fuel filter(s).

•Varnished carburetor

If the engine starts hard or will not start, look for the following:

•Physical damage to the AC generator. Check the Rotor for contact with the Stator.

•Starting under load. Make sure all loads are discon- nected or turned off before attempting to crank and start the engine.

•Check that the choke is working properly.

1.Remove fuel line at carburetor and ensure that there is an adequate amount of fuel entering the carburetor.

2.Remove the float bowl and check to see if there is any foreign matter in bottom of carburetor bowl.

3.The float is plastic and can be removed for access to the needle so it can be cleaned.

4.With all of this removed carburetor cleaner can be used to clean the rest of the carburetor before reassembly.

5.After cleaning carburetor with an approved carburetor cleaner, blow dry with compressed air and reassemble.

Shelf life on gasoline is 30 days. Proper procedures need to be taken for carburetors so that the fuel doesn’t varnish over time. A fuel stabilizer must be used at all times in order to ensure that the fuel is fresh at all times.

RESULTS:

If carburetor is varnished, clean or replace. Refer to Flow Chart.

Test 40 - Valve Adjustment

Adjusting Valve Clearance:

The valve lash must be adjusted correctly in order to pro- vide the proper air/fuel mixture to the combustion chamber.

Adjust valve clearance with the engine at room tem- perature. The piston should be at top dead center (TDC) of its compression stroke (both valves closed).

An alternative method is to turn the engine over and position the intake valve fully open (intake valve spring compressed) and adjust the exhaust valve clearance. Turn the engine over and position the exhaust valve fully open (exhaust valve spring compressed) and adjust the intake valve clearance.

Correct valve clearance is given below.

Intake Valve

0.002-0.004 inch (0.05-0.1 mm)

Exhaust Valve

0.002-0.004 inch (0.05-0.1 mm)

FEELER GAUGE

 

ALLEN WRENCH

Figure 6-51. – Adjusting Valve Clearance

1.Loosen the rocker arm jam nut. Use a 10mm allen wrench to turn the pivot ball stud while checking the clearance between the rocker arm and valve stem with a feeler gauge (see Figure 6-51).

2.When clearance is correct, hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut to the specified torque with a crow's foot. After tightening the jam nut, recheck valve clearance to make sure it did not change.

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Disassembly and Exploded Views 66-71 Magnetism Electromagnetic FieldsElectromagnetic Induction STATORs AC power windings Simple AC GeneratorMore Sophisticated AC Generator Generator Operating Diagram Meters Measuring AC VoltageVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawRotor Assembly Introduction AC GeneratorEngine-Generator Drive System Stator Assembly Brush Holder and BrushesOther AC Generator Components Excitation Circuit BreakerUnderfrequency Adjust 162Voltage Regulator Rotor Residual Magnetism Field Boost CircuitOperation Insulation Resistance MegohmmeterStator Insulation Resistance Test Testing ALL Stator Windings to Ground Test Between WindingsCleaning the Generator Rotor Insulation Resistance TestDrying the Generator Battery Recommended BatteryPrinted Circuit Board Circuit Board ConnectionsControl Panel Component Identification ENGINE DC CONTROLC1 Female Side C1 Male Side C2 Female Side C2 Male SideTerminal Block Terminal BLOCKTB2 TB1 Page Circuit Condition Rest = 12 VDC Control Circuit Condition Start IM1 SP1 IM2 SP2 RED Black Battery Circuit Condition RUN = Idle Control Transformer Output CIRcUIT Condition Stop Fault Shutdown If Problem Involves AC Output Problem 1 Voltage & Frequency Are Both High or LowIntroduction Or Replace If BAD Load Watts Problem 4 No Battery Charge Output Problem 5 No 10A Battery Charge OutputProblem 6 Engine Will Not Crank Problem 7 Engine Cranks But Will Not Start Problem 8 Engine Starts Hard and Runs Rough Problem 9 Engine Starts Then Shuts DownProblem 10 10 Amp Fuse F1 Blowing Problem 11 Unit Overspeeds Problem 12 Idle Control RPM Does Not DecreaseProblem 14 Engine Hunts / Erratic Idle Procedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Main Circuit Breaker ResultsTest 4 Fixed Excitation Test Rotor AMP Draw If circuit breaker is good, go on to TestSet voltmeter to measure AC voltage AC Voltage across Wires 11S and 44S= Refer to Test 4 Results chartRemove air cleaner cover to access stepper motor Set a voltmeter to measure resistanceTest 6 Wire Continuity Test 7 Check Field BoostDisconnect both wires from the Resistor R1 Test 8 DIODE/RESISTORSet volt meter to the diode test range Set volt meter to measure resistanceFrom the 50 Amp receptacle disconnect Wire Test 9 Test StatorUnplug the six pin connector at the Voltage Regulator Test 10 Sensing LeadsTest 11 Excitation Wiring Gain access to the brushes and slip ringsTest 12 Check Brush Leads Test 13 Check Brushes & Slip RingsTest 14 Check Rotor Assembly Test 15 Check Load Voltage FrequencyTest 16 Check Load Watts & Amperage If the unit is overloaded, reduce the loadTest 17 Check Battery Charge Output Test 19 Check Battery Charge Rectifier BCR2Disconnect all wires from the Battery Charge Rectifier Test 22- Check Battery & Cables Test 21- Check 10 Amp FuseBCR1BCR2 Refer back to flow chart Test 23 Check Voltage at Starter Contactor SCTest 24 Check Starter Contactor SC Test 25 Check Starter MotorChecking the Pinion Tools for Starter Performance TestTest 26 Test Starter Contactor Relay SCR Set voltmeter to measure DC voltageTest 27 Check Start-Run-Stop Switch SW1 Test 28 Check Start-Run-Stop Switch SW1 WiringReconnect all wires to the switch Procedure Set voltmeter to measure resistanceRefer back to the Flow Chart Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 31 Remove Wire 18 / Shutdown Lead Refer to Flow ChartSSR and the Battery Charge Rectifier 2 BCR2 Test 32 Test Start Stop Relay SSRTest 33 Test Wire RUNTest 34 Test Start Stop Relay Wiring Test 35 Check and Adjust IgnitionMagnetos Test 36 Test Fuel Shutoff Solenoid FSS Test 37 Test Fuel Shutoff Solenoid VoltageTest 38 Check Fuel Pump MagnetoTest 40 Valve Adjustment Adjusting Valve ClearanceTest 39 Check Carburetion Adjust the regulated pressure on the gauge to 80 psi 52 Tightening the Jam NutTest 42 Check Oil Pressure Switch Wire Test 43 Check Start Stop Relay SSRTest 45 Check Wire 15 Circuit Test 46 Check Wire 14 CircuitTest 44 Test Starter Contactor Relay SCR Test 47 Check Fuel Shutoff SolenoidTest 50 Check Wire Test 49 Check Wire 15BTest 51 Check Wires 11S & 44S Test 48 Check HourmeterTest 52 Check Idle Control Switch Test 53 Check Idle Control WiringSW2 TB2Test 55 Check TR1 & TR2 Wiring Test 54 Check Idle Control Transformers ICTTest 56 Choke Test Continuity should be measuredMajor Disassembly Remove air deflector Figure B, Item #45 from cross memberSupport Alternator 3317 3026 20 22 25 QTY Description Detail of Battery Tray QTY. Description ELECTRICAL DATA RED Battery Charge Winding BA Brush Assembly Governor Actuator 167 229 15B Power Winding DPE Winding SCR Wiring Diagram 17.5 kW Drawing No G0731 Stator Closest to Bearing Electrical Schematic 17.5 kW Drawing No G0733 Circuit 11 ORG Circuit 13 DRK BLU Circuit 15 PNK ELECTRICAL DATA Page Rated Max DC Load Amperes Current @ 12 Volts Load %Frequency Hz 238-242 59-61 100 Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI

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