Guardian Technologies 4270 manual OF4996 REV. O

Page 100

PO BOX 297 • WHITEWATER, WI 53190 • www.guardiangenerators.com

P/N OF4996 REV. O

PRINTED IN THE USA/1.05

Image 100

Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents 57-59 Electromagnetic Fields MagnetismElectromagnetic Induction Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostLine Breakers 120 VAC only Connection for 120/240 VAC Dual Voltage Rotor Assembly LIC Grit or Abrasive to Clean Slip RingsBattery Charge Components Brush HolderExcitation Circuit Components GeneralAdjust POT LED Adjustment Procedure162 Voltage RegulatorControl Panel Component Identification Control Panel ComponentsCleaning the Generator Effects of Dirt and MoistureDrying the Generator Insulation Resistance TestersBrushing and Vacuum Cleaning Stator Insulation ResistanceCloth or Compressed AIR Stator SHORT-TO-GROUND TestsTesting Rotor Insulation MegohmmeterMeters VOMMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring AC FrequencyMeasuring Resistance Electrical Units Ohms LAWOperational Analysis IntroductionCircuit CONDITION- OFF Circuit CONDITION- PRE-HEAT Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Circuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdowns Battery Engine Control Circuit BoardEffects of Temperature Checking Battery State of ChargeCharging a Battery Adding WaterPreheat Switch START/STOP SwitchAMP Fuse Starter Contactor & MotorEngine Governor Fuel Injection PumpFuel NOZZLES/INJECTORS Glow PlugsLOW OIL Pressure Switch High Coolant Temperature Switch Adapter LOW OIL Pressure SwitchEngine Protective Devices Overspeed ProtectionTroubleshooting Flowcharts Troubleshooting Flowcharts Problem 3 No Battery Charge Output Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Test 2 Check & Adjust Test 1- Check NO-LOAD Voltage FrequencyTest 3- Test Excitation Circuit Breaker Test 4- Fixed Excitation TEST/ROTOR AMP DrawTest 5- Wire Continuity Re-connect Wire 11 and Wire 22 to the Voltage RegulatorTest 6- Check Field Boost Set a VOM to its Rx1 scaleTest 7 Test Stator DPE Winding Model QP75DTest 8- Check Sensing Leads / Power Windings Test 9- Check Brush Leads159W 184WTance Tests Procedure Test 11- Check Rotor AssemblyTest 10 Check Brushes & Slip Rings Test 15 Check Battery Charge Output Test 12 Check Main Circuit BreakerTest 13- Check Load Voltage Frequency Test 14- Check Load Watts & AmperageBattery Charge Rectifier BCR is a full wave rectifier Test 16 Check Battery Charge RectifierShort to Ground Test 19- Test PRE-HEAT Switch Set a VOM to read battery voltage 12 VDCTest 18 TRY Cranking the Engine Test 20- Check Fuel PumpTest 22- Check Battery & Cables Test 23- Check Power Supply to Circuit BoardDisconnect the connector from the wires of the fuel pump Test 21- Check 14 AMP FuseTest 24 Check START-STOP Switch Not ActivatedTest 27 Check Starter Motor Test 26- Test Starter ContactorConditions Affecting Starter Motor Performance Checking the Pinion PinionTools for Starter Performance Test Measuring CurrentTesting Starter Motor TachometerTest Bracket Starter motor test bracket may be made as shown in FigureTest 29 Check Wire 14 Power Supply Test 30 Check WireIf Wire 18 checks GOOD, proceed to Problem 8 Section Test 28- Check Fuel SupplyTest 33- Test Glow Plugs Test 32- Test Preheat ContactorTest 34- Test D1 Diode Remove the valve cover from engine Disconnect the battery Test 35- Check Valve AdjustmentTest 36- Fuel Injector Pump If fuel is noted, proceed to next step in flowchart Adjust the regulated pressure on the gauge to 80 psiDown Test / Compression Test Repeat Steps 1 through 8 on remaining cylinderTest 40- Test Water Temperature Switch Test 38 Check OIL Pressure SwitchTest 39- Check Circuit Board for Ground If continuity is measure, replace the switch Test 43 Check Wire 15 for Short to GroundComponents for Short to Ground Major Disassembly RE-ASSEMBLY Belt TensioningLine Corner UP Between 5˚ to 10˚ FAN BeltSection Exploded Views / Part Numbers Rotor Assembly Stator AssemblyFlywheel Assembly Bearing Carrier, FrontBase Frame Drawing No D2357-A Door, Service Rear Door, Service FrontBase Frame Weldment Slide Latch FlushEnclosure Drawing No D2358-D Cover, Access Lift Cover, Access ElectricalGasket, Electrical Access Decal, Battery +Views / Part Cover Plate, Scroll Weldment 25 26 Assembly, Potted Regulator Assembly Marine Control BoardRectifier, Battery Charging Wire Assembly #Intake and Exhaust System Drawing No D2362-B Exhaust Gasket Chamber Air IntakeAir Filter Hose, Air InletViews / Part Numbers Fuel Pump Assembly Boot, Battery CableCable, Battery Wire Assembly, Black #4 GroundCustomer Controls Assembly Drawing No D2364-D Start / Stop Switch Switch, Pushbutton SpstBoot / Nut / Preheat Switch Boot, Circuit BreakerCamshaft Assembly Camshaft GearKEY Gear2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B Idler Gear Assembly SpringThrust Washer OIL Pump CoverRocker ARM Assembly Includes ALL Components Shown belowIntake Rocker ARM Exhaust Rocker ARMLiter Diesel Injector Pump Drawing No -C Tank Return Model 04270 To Injection Pump To Fuel Pump 27 25 19 18 HOUSING, Timing Gear 3114 Liter Diesel Water Pump Drawing No Charts Engine Specifications Generator SpecificationsROTOR/STATOR Resistance Values Type Quietpact ModelPage Data Data Electrical Data Schematic Drawing No C4945-A Model C4945Electrical C4946-ASheet 2 OF4996 REV. O