Guardian Technologies 4270 manual Safety, Replacement Parts

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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, IF NOT COM- PLIED WITH, COULD RESULT IN PERSONAL INJURY OR DEATH.

CAUTION! Under this heading will be found special instructions which, if not complied with, could result in damage to equipment and/or property.

These "Safety Alerts" alone cannot eliminate the hazards that they signal. Strict compliance with these spe- cial Instructions plus "common sense" are major accident prevention measures.

NOTICE TO USERS OF THIS MANUAL

This SERVICE MANUAL has been written and published by Generac to aid our dealers, mechanics, and company service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures for these products, or similar products manufactured and marketed by Generac; that they have been trained in the recommended servic- ing procedures for these products, including the use of common hand tools, special Generac tools, or tools from other suppliers.

Generac could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. Generac has not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or tool not recommended by Generac, must ensure that neither personal safety nor the products safety will be endangered by the service procedure selected.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication.

When working on these products, remember that the electrical system and engine ignition system are capa- ble of violent and damaging short circuits or severe electrical shocks. If work must be done where electrical terminals could be grounded or touched, the battery cables should be disconnected at the battery.

Any time the intake or exhaust openings of the engine are exposed during service, they should be covered to prevent accidental entry of foreign material. Entry of such materials will result in extensive damage when the engine is started.

During any maintenance procedure, replacement fasteners must have the same measurements and strength as the fasteners that were removed. Metric bolts and nuts have numbers that indicate their strength. Customary bolts use radial lines to indicate strength, while most customary nuts do not have strength mark- ings. Mismatched or incorrect fasteners can cause damage, malfunction and possible injury.

REPLACEMENT PARTS

Components on Generac recreational vehicle generators are designed and manufactured to comply with Recreational Vehicle Industry Association (RVIA) Rules and Regulations to minimize the risk of fire or explo- sion. The use of replacement parts that are not in compliance with such Rules and Regulations could result in a fire or explosion hazard. When servicing this equipment, It is extremely important that all components be properly installed and tightened. If parts are improperly installed or tightened, sparks could ignite fuel vapors from fuel system leaks.

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents 57-59 Electromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Line Breakers 120 VAC only Field BoostGenerator AC Connection System Connection for 120/240 VAC Dual Voltage Rotor Assembly LIC Grit or Abrasive to Clean Slip RingsExcitation Circuit Components Battery Charge ComponentsBrush Holder General162 Adjust POT LEDAdjustment Procedure Voltage RegulatorControl Panel Component Identification Control Panel ComponentsDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersCloth or Compressed AIR Brushing and Vacuum CleaningStator Insulation Resistance Stator SHORT-TO-GROUND TestsTesting Rotor Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Resistance Measuring AC FrequencyMeasuring Current Electrical Units Ohms LAWCircuit CONDITION- OFF IntroductionOperational Analysis Circuit CONDITION- PRE-HEAT Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Circuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdowns Battery Engine Control Circuit BoardCharging a Battery Effects of TemperatureChecking Battery State of Charge Adding WaterAMP Fuse Preheat SwitchSTART/STOP Switch Starter Contactor & MotorFuel NOZZLES/INJECTORS Engine GovernorFuel Injection Pump Glow PlugsEngine Protective Devices LOW OIL Pressure Switch High Coolant Temperature SwitchAdapter LOW OIL Pressure Switch 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 6- Check Field Boost Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Set a VOM to its Rx1 scaleTest 7 Test Stator DPE Winding Model QP75D159W Test 8- Check Sensing Leads / Power WindingsTest 9- Check Brush Leads 184WTest 10 Check Brushes & Slip Rings Test 11- Check Rotor AssemblyTance Tests Procedure Test 13- Check Load Voltage Frequency Test 15 Check Battery Charge OutputTest 12 Check Main Circuit Breaker Test 14- Check Load Watts & AmperageShort to Ground Test 16 Check Battery Charge RectifierBattery Charge Rectifier BCR is a full wave rectifier Test 18 TRY Cranking the Engine Test 19- Test PRE-HEAT SwitchSet a VOM to read battery voltage 12 VDC Test 20- Check Fuel PumpDisconnect the connector from the wires of the fuel pump Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board Test 21- Check 14 AMP FuseTest 24 Check START-STOP Switch Not ActivatedConditions Affecting Starter Motor Performance Test 26- Test Starter ContactorTest 27 Check Starter Motor Tools for Starter Performance Test Checking the PinionPinion Measuring CurrentTest Bracket Testing Starter MotorTachometer Starter motor test bracket may be made as shown in FigureIf Wire 18 checks GOOD, proceed to Problem 8 Section Test 29 Check Wire 14 Power SupplyTest 30 Check Wire Test 28- Check Fuel SupplyTest 34- Test D1 Diode Test 32- Test Preheat ContactorTest 33- Test Glow Plugs Test 36- Fuel Injector Pump Test 35- Check Valve AdjustmentRemove the valve cover from engine Disconnect the battery Down Test / Compression Test If fuel is noted, proceed to next step in flowchartAdjust the regulated pressure on the gauge to 80 psi Repeat Steps 1 through 8 on remaining cylinderTest 39- Check Circuit Board for Ground Test 38 Check OIL Pressure SwitchTest 40- Test Water Temperature Switch Components for Short to Ground Test 43 Check Wire 15 for Short to GroundIf continuity is measure, replace the switch Major Disassembly RE-ASSEMBLY Belt TensioningLine Corner UP Between 5˚ to 10˚ FAN BeltSection Exploded Views / Part Numbers Flywheel Assembly Rotor AssemblyStator Assembly Bearing Carrier, FrontBase Frame Drawing No D2357-A Base Frame Weldment Door, Service RearDoor, Service Front Slide Latch FlushEnclosure Drawing No D2358-D Gasket, Electrical Access Cover, Access LiftCover, Access Electrical Decal, Battery +Views / Part Cover Plate, Scroll Weldment 25 26 Rectifier, Battery Charging Assembly, Potted RegulatorAssembly Marine Control Board Wire Assembly #Intake and Exhaust System Drawing No D2362-B Air Filter Exhaust GasketChamber Air Intake Hose, Air InletViews / Part Numbers Cable, Battery Fuel Pump AssemblyBoot, Battery Cable Wire Assembly, Black #4 GroundCustomer Controls Assembly Drawing No D2364-D Boot / Nut / Preheat Switch Start / Stop SwitchSwitch, Pushbutton Spst Boot, Circuit BreakerKEY Camshaft AssemblyCamshaft Gear Gear2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B Thrust Washer Idler Gear AssemblySpring OIL Pump CoverIntake Rocker ARM Rocker ARM AssemblyIncludes ALL Components Shown below 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. 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