Guardian Technologies 4451 & 4986, 4582 & 4987, 4583, 5308 manual Tightening the Jam Nut

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Section 6

DIAGNOSTIC TESTS

TORQUE SPECIFICATION ROCKER ARM JAM NUT 168 inch-pounds (19 Nm)

CROW'S FOOT

Figure 6-52 – Tightening the Jam Nut

Install Rocker Arm Cover

1.Use a new rocker arm cover gasket. Install the rocker arm cover and retain with four screws.

Results:

Adjust valves to specification and retest. If problem continues, refer to Flow Chart.

Test 41 - Check Engine / Cylinder Leak

Down Test / Compression Test

Most engine problems may be classified as one or a combination of the following:

•Will not start.

•Starts hard.

•Lack of power.

•Runs rough.

•Vibration.

•Overheating.

•High oil consumption.

The Cylinder Leak Down Tester (Generac P/N 0F77000SRV) checks the sealing (compression) abil- ity of the engine by measuring air leakage from the combustion chamber. Compression loss can present many different symptoms. This test is designed to detect the section of the engine where the fault lies before disassembling the engine.

Procedure:

1.Remove a spark plug.

2.Gain access to the flywheel. Remove the valve cover.

3.Rotate the engine crankshaft until the piston reaches top dead center (TDC). Both valves should be closed.

4.Lock the flywheel at top dead center.

5.Attach cylinder leak down tester adapter to spark plug hole.

6.Connect an air source of at least 90 psi to the leak down tester.

7.Adjust the regulated pressure on the gauge to 80 psi.

8.Read the right hand gauge on the tester for cylinder pressure. 20 percent leakage is normally acceptable. Use good judgement, and listen for air escaping at the carburetor, the exhaust, and the crankcase breather. This will determine where the fault lies.

9.Repeat Steps 1 through 8 on remaining cylinder.

Results:

•Air escapes at the carburetor – check intake valve.

•Air escapes through the exhaust – check exhaust valve.

•Air escapes through the breather – check piston rings.

•Air escapes from the cylinder head – the head gas- ket should be replaced.

Check Compression:

Lost or reduced engine compression can result in (a) failure of the engine to start, or (b) rough operation. One or more of the following will usually cause loss of compression:

•Blown or leaking cylinder head gasket.

•Improperly seated or sticking-valves.

•Worn Piston rings or cylinder. (This will also result in high oil consumption).

PROCEDURE:

1.Remove both spark plugs.

2.Insert a compression gauge into either cylinder.

3.Crank the engine until there is no further increase in pressure.

4.Record the highest reading obtained.

5.Repeat the procedure for the remaining cylinder and record the highest reading.

RESULTS:

Normal compression is approximately 150 psi. The dif- ference in pressure between the two cylinders should not exceed 25 percent. If the difference is greater than 25 percent, loss of compression in the lowest reading cylinder is indicated.

Example 1: If the pressure reading of cylinder #1 is 165 psi and of cylinder #2, 160 psi, the difference is 5 psi. Divide "5" by the highest reading (165) to obtain the percentage of 3.0 percent.

Example 2: No. 1 cylinder reads 160 psi; No. 2 cylinder reads 100 psi. The difference is 60 psi. Divide "60" by "160" to obtain "37.5" percent. Loss of compression in No. 2 cylinder is indicated.

If compression is poor, look for one or more of the fol- lowing causes:

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Disassembly and Exploded Views 66-71 Electromagnetic Fields MagnetismElectromagnetic Induction Simple AC Generator STATORs AC power windingsMore Sophisticated AC Generator Generator Operating Diagram Measuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Resistance Measuring CurrentOhms Law Electrical UnitsIntroduction AC Generator Rotor AssemblyEngine-Generator Drive System Brush Holder and Brushes Stator AssemblyOther AC Generator Components Excitation Circuit Breaker162 Underfrequency AdjustVoltage Regulator Field Boost Circuit Rotor Residual MagnetismOperation Megohmmeter Insulation ResistanceStator Insulation Resistance Test Test Between Windings Testing ALL Stator Windings to GroundRotor Insulation Resistance Test Cleaning the GeneratorDrying the Generator Recommended Battery BatteryPrinted Circuit Board Circuit Board ConnectionsENGINE DC CONTROL Control Panel Component IdentificationC2 Female Side C2 Male Side C1 Female Side C1 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 Problem 1 Voltage & Frequency Are Both High or Low If Problem Involves AC OutputIntroduction Or Replace If BAD Load Watts Problem 5 No 10A Battery Charge Output Problem 4 No Battery Charge OutputProblem 6 Engine Will Not Crank Problem 7 Engine Cranks But Will Not Start Problem 9 Engine Starts Then Shuts Down Problem 8 Engine Starts Hard and Runs RoughProblem 10 10 Amp Fuse F1 Blowing Problem 12 Idle Control RPM Does Not Decrease Problem 11 Unit OverspeedsProblem 14 Engine Hunts / Erratic Idle Test 1 Check No-Load Voltage Frequency ProcedureTest 2 Check Main Circuit Breaker ResultsIf circuit breaker is good, go on to Test Test 4 Fixed Excitation Test Rotor AMP DrawSet voltmeter to measure AC voltage Refer to Test 4 Results chart AC Voltage across Wires 11S and 44S=Set a voltmeter to measure resistance Remove air cleaner cover to access stepper motorTest 7 Check Field Boost Test 6 Wire ContinuityTest 8 DIODE/RESISTOR Disconnect both wires from the Resistor R1Set volt meter to the diode test range Set volt meter to measure resistanceTest 9 Test Stator From the 50 Amp receptacle disconnect WireTest 10 Sensing Leads Unplug the six pin connector at the Voltage RegulatorGain access to the brushes and slip rings Test 11 Excitation WiringTest 12 Check Brush Leads Test 13 Check Brushes & Slip RingsTest 15 Check Load Voltage Frequency Test 14 Check Rotor AssemblyTest 16 Check Load Watts & Amperage If the unit is overloaded, reduce the loadTest 19 Check Battery Charge Rectifier BCR2 Test 17 Check Battery Charge OutputDisconnect all wires from the Battery Charge Rectifier Test 21- Check 10 Amp Fuse Test 22- Check Battery & CablesBCR1BCR2 Test 23 Check Voltage at Starter Contactor SC Refer back to flow chartTest 24 Check Starter Contactor SC Test 25 Check Starter MotorTools for Starter Performance Test Checking the PinionSet voltmeter to measure DC voltage Test 26 Test Starter Contactor Relay SCRTest 28 Check Start-Run-Stop Switch SW1 Wiring Test 27 Check Start-Run-Stop Switch SW1Reconnect all wires to the switch Procedure Set voltmeter to measure resistanceTest 29 Check Ignition Spark Refer back to the Flow ChartTest 30 Check Spark Plugs Refer to Flow Chart Test 31 Remove Wire 18 / Shutdown LeadSSR and the Battery Charge Rectifier 2 BCR2 Test 32 Test Start Stop Relay SSRRUN Test 33 Test WireTest 35 Check and Adjust Ignition Test 34 Test Start Stop Relay WiringMagnetos Test 37 Test Fuel Shutoff Solenoid Voltage Test 36 Test Fuel Shutoff Solenoid FSSTest 38 Check Fuel Pump MagnetoAdjusting Valve Clearance Test 40 Valve AdjustmentTest 39 Check Carburetion 52 Tightening the Jam Nut Adjust the regulated pressure on the gauge to 80 psiTest 43 Check Start Stop Relay SSR Test 42 Check Oil Pressure Switch WireTest 46 Check Wire 14 Circuit Test 45 Check Wire 15 CircuitTest 44 Test Starter Contactor Relay SCR Test 47 Check Fuel Shutoff SolenoidTest 49 Check Wire 15B Test 50 Check WireTest 51 Check Wires 11S & 44S Test 48 Check HourmeterTest 53 Check Idle Control Wiring Test 52 Check Idle Control SwitchSW2 TB2Test 54 Check Idle Control Transformers ICT Test 55 Check TR1 & TR2 WiringContinuity should be measured Test 56 Choke TestRemove air deflector Figure B, Item #45 from cross member Major DisassemblySupport 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 Load % Rated Max DC Load Amperes Current @ 12 VoltsFrequency Hz 238-242 59-61 100 Trim Torque Specifications Torque SpecificationsPO BOX 297 WHITEWATER, WI

5308, 4583, 4451 & 4986, 4582 & 4987 specifications

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