Guardian Technologies 4270 manual

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents 57-59 Magnetism Electromagnetic FieldsElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemLine Breakers 120 VAC only Connection for 120/240 VAC Dual Voltage LIC Grit or Abrasive to Clean Slip Rings Rotor AssemblyBrush Holder Battery Charge ComponentsExcitation Circuit Components GeneralAdjustment Procedure Adjust POT LED162 Voltage RegulatorControl Panel Components Control Panel Component IdentificationEffects of Dirt and Moisture Cleaning the GeneratorDrying the Generator Insulation Resistance TestersStator Insulation Resistance Brushing and Vacuum CleaningCloth or Compressed AIR Stator SHORT-TO-GROUND TestsMegohmmeter Testing Rotor InsulationVOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring AC Frequency Measuring CurrentMeasuring Resistance Ohms LAW Electrical UnitsIntroduction Operational AnalysisCircuit CONDITION- OFF Circuit CONDITION- PRE-HEAT Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Circuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdowns Engine Control Circuit Board BatteryChecking Battery State of Charge Effects of TemperatureCharging a Battery Adding WaterSTART/STOP Switch Preheat SwitchAMP Fuse Starter Contactor & MotorFuel Injection Pump Engine GovernorFuel NOZZLES/INJECTORS Glow PlugsAdapter LOW OIL Pressure Switch LOW OIL Pressure Switch High Coolant Temperature 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 1- Check NO-LOAD Voltage Frequency Test 2 Check & AdjustTest 4- Fixed Excitation TEST/ROTOR AMP Draw Test 3- Test Excitation Circuit BreakerRe-connect Wire 11 and Wire 22 to the Voltage Regulator Test 5- Wire ContinuityTest 6- Check Field Boost Set a VOM to its Rx1 scaleModel QP75D Test 7 Test Stator DPE WindingTest 9- Check Brush Leads Test 8- Check Sensing Leads / Power Windings159W 184WTest 11- Check Rotor Assembly Tance Tests ProcedureTest 10 Check Brushes & Slip Rings Test 12 Check Main Circuit Breaker Test 15 Check Battery Charge OutputTest 13- Check Load Voltage Frequency Test 14- Check Load Watts & AmperageTest 16 Check Battery Charge Rectifier Battery Charge Rectifier BCR is a full wave rectifierShort to Ground Set a VOM to read battery voltage 12 VDC Test 19- Test PRE-HEAT SwitchTest 18 TRY Cranking the Engine Test 20- Check Fuel PumpTest 23- Check Power Supply to Circuit Board Test 22- Check Battery & CablesDisconnect the connector from the wires of the fuel pump Test 21- Check 14 AMP FuseNot Activated Test 24 Check START-STOP SwitchTest 26- Test Starter Contactor Test 27 Check Starter MotorConditions Affecting Starter Motor Performance Pinion Checking the PinionTools for Starter Performance Test Measuring CurrentTachometer Testing Starter MotorTest Bracket Starter motor test bracket may be made as shown in FigureTest 30 Check Wire Test 29 Check Wire 14 Power SupplyIf Wire 18 checks GOOD, proceed to Problem 8 Section Test 28- Check Fuel SupplyTest 32- Test Preheat Contactor Test 33- Test Glow PlugsTest 34- Test D1 Diode Test 35- Check Valve Adjustment Remove the valve cover from engine Disconnect the batteryTest 36- Fuel Injector Pump Adjust the regulated pressure on the gauge to 80 psi If fuel is noted, proceed to next step in flowchartDown Test / Compression Test Repeat Steps 1 through 8 on remaining cylinderTest 38 Check OIL Pressure Switch Test 40- Test Water Temperature SwitchTest 39- Check Circuit Board for Ground Test 43 Check Wire 15 for Short to Ground If continuity is measure, replace the switchComponents for Short to Ground Major Disassembly Belt Tensioning RE-ASSEMBLYFAN Belt Line Corner UP Between 5˚ to 10˚Section Exploded Views / Part Numbers Stator Assembly Rotor AssemblyFlywheel Assembly Bearing Carrier, FrontBase Frame Drawing No D2357-A Door, Service Front Door, Service RearBase Frame Weldment Slide Latch FlushEnclosure Drawing No D2358-D Cover, Access Electrical Cover, Access LiftGasket, Electrical Access Decal, Battery +Views / Part Cover Plate, Scroll Weldment 25 26 Assembly Marine Control Board Assembly, Potted RegulatorRectifier, Battery Charging Wire Assembly #Intake and Exhaust System Drawing No D2362-B Chamber Air Intake Exhaust GasketAir Filter Hose, Air InletViews / Part Numbers Boot, Battery Cable Fuel Pump AssemblyCable, Battery Wire Assembly, Black #4 GroundCustomer Controls Assembly Drawing No D2364-D Switch, Pushbutton Spst Start / Stop SwitchBoot / Nut / Preheat Switch Boot, Circuit BreakerCamshaft Gear Camshaft AssemblyKEY Gear2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B Spring Idler Gear AssemblyThrust Washer OIL Pump CoverIncludes ALL Components Shown below Rocker ARM AssemblyIntake 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 Generator Specifications Engine SpecificationsType Quietpact Model ROTOR/STATOR Resistance ValuesPage Data Data Electrical Data C4945 Schematic Drawing No C4945-A ModelC4946-A ElectricalSheet 2 OF4996 REV. 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