Guardian Technologies 4270 manuals
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Guardian Technologies 4270 Manual
100 pages 9.26 Mb
2 SAFETYNOTICE TO USERS OF THIS MANUAL REPLACEMENT PARTS3 Table of ContentsSECTION 2: MAJOR GENERATOR COMPONENTS............ 8-11 SECTION 3: INSULATION RESISTANCE TESTS ............ 12-14 SECTION 4: MEASURING ELECTRICITY ........................ 15-17 SECTION 5: ENGINE DC CONTROL SYSTEM ................ 18-28 SECTION 6: TROUBLESHOOTING FLOWCHARTS .................. 29-36 SECTION 7: DIAGNOSTIC TESTS...................................... 37-57 4 Table of ContentsSECTION 8: ASSEMBLY .................................................... 57-59 SECTION 11: ELECTRICAL DATA ............................................ 92 5 MAGNETISMFigure 1-1. Magnetic Lines of Force ELECTROMAGNETIC FIELDSFigure 1-2. The Right Hand Rule ELECTROMAGNETIC INDUCTIONFigure 1-3. A Simple Revolving Field Generator 6 A SIMPLE AC GENERATORFigure 1-4. A Simple AC Generator Figure 1-5. Alternating Current Sine Wave A MORE SOPHISTICATED AC GENERATOR 8 FIELD BOOSTGENERATOR AC CONNECTION SYSTEM GENERATOR CONVERSION TO 120 VAC ONLY DUAL CIRCUITS 10 ROTOR ASSEMBLYFigure 2-1. Exploded View of Generator STATOR ASSEMBLYFigure 2-2. Stator Output Leads 11 BRUSH HOLDERBATTERY CHARGE COMPONENTSFigure 2-4. Battery Charge Circuit EXCITATION CIRCUIT COMPONENTSFigure 2-5. Schematic: Excitation Circuit 14 EFFECTS OF DIRT AND MOISTUREINSULATION RESISTANCE TESTERSFigure 3-1. One Type of Hi-Pot Tester DRYING THE GENERATOR CLEANING THE GENERATOR 15 STATOR INSULATION RESISTANCE16 TESTING ROTOR INSULATIONFigure 3-3. Rotor Test Points THE MEGOHMMETER 17 METERSTHE VOM MEASURING AC VOLTAGE MEASURING DC VOLTAGE 18 MEASURING AC FREQUENCYMEASURING CURRENTFigure 4-2. Clamp-On Ammeter MEASURING RESISTANCE ELECTRICAL UNITSFigure 4-4. Electrical Units OHM'S LAWFigure 4-5. AMPERES = VOLTS OHMS VOLTS = AMPERES x OHMS OHMS = VOLTS AMPERES 19 -20 OPERATIONAL ANALYSIS26 ENGINE CONTROL CIRCUIT BOARDBATTERY 28 14 AMP FUSEFigure5-4 Figure 5-7. Starter Contactor and Connections PREHEAT SWITCHFigure 5-5. Pre-heat Switch START/STOP SWITCHFigure 5-6. Start/Stop Switch STARTER CONTACTOR & MOTOR 29 ENGINE GOVERNORFUEL INJECTION PUMPFigure 5-8. Fuel Injection Pump FUEL NOZZLES/INJECTORSFigure 5-9. Fuel Injectors Figure 5-10. Fuel Injector Nozzles GLOW PLUGS 30 ENGINE PROTECTIVE DEVICESLOW OIL PRESSURE SWITCH HIGH COOLANT TEMPERATURE SWITCHFigure 5-13. High Coolant Temperature Switch OVERSPEED PROTECTIONSection 6 TROUBLESHOOTING FLOWCHARTS 33 GPage 31 Problem 2 - Generator Produces ZeroVoltage or Residual Voltage (5-12VAC) (continued) Problem 3 - No Battery Charge Output E F39 TEST 1- CHECK NO-LOAD VOLTAGE AND FREQUENCYTEST 2 - CHECK & ADJUST ENGINE GOVERNORFigure 7-1. Governor Adjustment Points 40 TEST 3- TEST EXCITATION CIRCUIT BREAKERNote: After running the unit, allow two minutes for the breaker to reset. Figure 7-2. Excitation DPE Circuit Breaker TEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAWFigure 7-3. Fixed Excitation Test 41 TEST 5- WIRE CONTINUITYTEST 6- CHECK FIELD BOOST 42 TEST 7 - TEST STATOR DPE WINDINGFigure 7-4. Stator Excitation Winding 43 TEST 8- CHECK SENSING LEADS / POWER WINDINGSFigure 7-5. Stator Power Winding Leads TEST 9- CHECK BRUSH LEADS 44 TEST 10 - CHECK BRUSHES & SLIP RINGSFigure 7-7. Rotor Assembly TEST 11- CHECK ROTOR ASSEMBLY 45 TEST 12 - CHECK MAIN CIRCUIT BREAKERFigure 7-8. Main Breaker (Typical) TEST 13- CHECK LOAD VOLTAGE & FREQUENCY TEST 14- CHECK LOAD WATTS & AMPERAGE TEST 15 - CHECK BATTERY CHARGE OUTPUT 46 TEST 16 - CHECK BATTERY CHARGE RECTIFIERFigure 7-9. Battery Charge Rectifier TEST 17 - CHECK BATTERY CHARGE WINDINGS / BATTERY CHARGE RESISTOR 47 TEST 18 - TRY CRANKING THE ENGINETEST 19- TEST PRE-HEAT SWITCHFigure 7-10. Pre-Heat Switch TEST 20- CHECK FUEL PUMP 48 TEST 21- CHECK 14 AMP FUSETEST 22- CHECK BATTERY & CABLES TEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD 49 TEST 24 - CHECK START-STOP SWITCHFigure 7-12. Start-Stop Switch Figure 7-13. Test 24, Step 6 TEST 25 - CHECK POWER SUPPLY TO WIRE 56 50 TEST 26- TEST STARTER CONTACTORTEST 27 - CHECK STARTER MOTOR51 Figure 7-14. Starter Motor (SM)Figure 7-15. Check Starter Pinion 52 Figure 7-16. Clamp-On AmmeterFigure 7-17. Tachometer Figure 7-19. Testing Starter Motor Performance Figure 7-18. Test Bracket Note: Take the reading after the ammeter and tachometer are stabilized, approximately 2-4 seconds. Note: Nominal amp draw of starter in generator is 60 amps. 53 TEST 28- CHECK FUEL SUPPLYTEST 29 - CHECK WIRE 14 POWER SUPPLY TEST 30 - CHECK WIRE 18Figure 7-20. Remote Harness Connector TEST 31 - CHECK FUEL SOLENOID 54 TEST 32- TEST PREHEAT CONTACTORTEST 33- TEST GLOW PLUGS TEST 34- TEST D1 DIODE 55 TEST 35- CHECK VALVE ADJUSTMENTFigure 7-21. Flywheel Position for Top Dead Center Figure 7-22. Valve Adjustment Points Figure 7-23. Checking Valve Adjustment TEST 36- FUEL INJECTOR PUMP 56 TEST 37 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TEST57 TEST 38 - CHECK OIL PRESSURE SWITCHFigure 7-23. Oil Pressure Switch TEST 39- CHECK CIRCUIT BOARD FOR GROUND TEST 40- TEST WATER TEMPERATURE SWITCH 58 TEST 41- CHECK WIRE 14 AND CONNECTING COMPONENTS FOR SHORT TO GROUNDTEST 42 - CHECK WIRE 56 AND STARTER CONTACTOR FOR SHORT TO GROUND. TEST 43 - CHECK WIRE 15 FOR SHORT TO GROUND 59 MAJOR DISASSEMBLYFigure 8-1. Block of Wood Under Rear of Engine Figure 8-2. Using Prybar to Stabilize Flywheel Figure 8-3. Radiator Removal Points 60 RE-ASSEMBLYBELT TENSIONINGFigure 8-4. Drive Belt Tensioner 91 ENGINE SPECIFICATIONSGENERATOR SPECIFICATIONS 92 ROTOR/STATOR RESISTANCE VALUES94 Page 92Wiring Diagram Drawing No. 0D2793-B (1 of 2) Models 04270-1 & 04270-2 Single 120/240VAC Output2 SHEET 1 OF 2TS SM BH2 GND4 ENGINE CONTROL T3 T1 04270-1 0D2793-BCOMPA RT M ENT CONTROL PANEL COMPA RT M ENT VOLT AGE REG U LATOR CB 2 BH1A BH1R2 BC R GND2 GND3 CONN 1 AVR RED 12V BA TTERY C O NNEC T ION CUS TO MER P RO VIDED WIRE DIAGRAM, 1.0L DSL SINGLE 120/240VAC OUTPUT 95 Page 93Wiring Diagram Drawing No. 0D2793-B (2 of 2) Models 04270-1 & 04270-2 Dual 120VAC 35A Output150 TS BH 2 BH 2A SM SHEET 2 OF 2 0D2793-BSW1 F1 AVR CONN 1 BCR D1 GLOW PLUGS LOS F CONTRO L ENGINE CONTRO L COMPARTMENT T3 VO L TA GE RE G U L ATOR COMPARTMENT PANE L JUMPERCUS TOMER PRO VIDED 12V B ATTERY CONNEC TION GND1 RED FS GND2 GND3 R1 CB 2 GND 4 BH 1A BH 1 WIRE DIAGRAM, 1.0L DSL SINGLE 120/240VAC OUTPUT Page 94 Schematic Drawing No. 0D2792-A Models 04270-1 & 04270-2SW1 -SWITCH, START/STOP F1 -FU SE 14AM P SFE 04270-1 120V 240VFOR DETAILS DIAGRAM SEE WIRING FP - FUEL PUM P D1 - DIODE 600V , 6AMP BCW - BATTE RY CHAR G ER SC -START CO NTACTOR S -START E R LOS - LOW OIL PR ESSUR E SWITCH R1 -R ESISTOR, 1 OH M, 25W CB 2 -CIRC UIT BR EAKER (4A) LEG ENDR2 -R ESISTOR, 20 OH M , 12W GP - GLOW P LUGS DPE - EXCITATION WINDING CB 1 -CIRC UIT BREA KER 35 A D2 - DIODE 600V , 6AMP FS - FUEL SO LENOID HWT -HI GH WAT ER T EMP SWITCH PHC -PR EHEAT CO N TACTOR SW -PR E HEAT SWITCH HM -HO URME TER BCR - BATTER Y CHAR GE R ECTIFIER AVR -A U TOMATIC VOLTAG E REGU LATOR 120V 35A 120V 35A *-WIRE #11 FOR 120V ONLY AC OUTP UT CO NNECTIO NSSM SC SC 12 6 5 7 2 1 ENGINE FP D2 R2 AVR F+ CB2 SW1 GP PHC SW PHC 15 HM REM OTE START/ BCW BCR R1 CB1 * 96 D2792-APage 95 Schematic Drawing No. 0C4945-A Model 04270-0SW1 -SWITCH, START/STOP F1 -FU SE 14AM P SFE RV L 97 CAC SCCB1 CB1A STOP CO NN ECTION SEN D1 DPE 120V 240VFOR DETAILS DIAGRAM SEE WIRING D1 - DIODE 600V , 6AMP BCW - BATT ERY CHAR G ER SC -START CO NTACTOR S -START E R LOS - LOW OIL PR ESSUR E SWITCH R1 -R ESISTOR, 1 OH M, 25W FP - FUEL PUM P CB 2 -CIRC UIT BR EAKER (4A) LEG ENDR2 -R ESISTOR, 20 OH M , 12W GP - GLOW P LUGS DPE - EXCITATION WINDING CB 1 -CIRC UIT BREA KER 35 A D2 - DIODE 600V , 6AMP FS - FUEL SO LENOID HWT -HI GH WAT ER T EMP SWITCH PHC -PR EHEAT CO NTACTOR SW -PR E HEAT SWITCH HM -HO URME TER BCR - BATTER Y CHAR GE R ECTIFIER AVR -A U TOMATIC VOLTAG E REGU LATOR 120V 120V 35A 120V 35A *-WIRE #11 FOR 120V ONLY AC OUTP UT CO NNECTIO NS A ASM SC SC 1 CO NTRO L 10 FP STOP 9 3 4 D2 R2 SEN AVR F+ F- DPE CB2 SW1 GP PHC SW PHC 15 HM BCW BCR FS CB1 HEMATI 1.0L DIE E 4945-1.0 Page 96 Wiring Diagram Drawing No. 0C4946-A (1 of 2) Model 04270-0 Single 120/240VAC Output 98 C18 17 15 150 T3 T1 ENGINE CONTROL LEGE ND SHEET 1 OF 2TS SM BH1 BH2A GND4 W S IRE DIAGRAM 90 0/ G 1.0L DSL IN LE 12 24 VA C OU TP U T 6 - AHWT LOS GLOW PLUGS SW2 D1 FP FS SW1 GND1 F1 GND5 BH2 BH1AGND2 GND3 CONN 1 AVR RED 12V BATTERY CONNEC TION CUSTOMER PROVIDED COMPARTMENT CONTROL PANEL COMPARTMENT VOLTAGE REGULATOR Page 97 Wiring Diagram Drawing No. 0C4946-A (2 of 2) Models 04270-0 Dual 120VAC 35A Output 99 C11 18 17 15 T1 VOLTAGE REGULATOR LEGE NDENGINE CONTROL COMPAR TMENT TS BH2 BH2A SM SHEET 2 OF 2 9 1.0L DSL UAL 120VAC 35A OUTPUT 6 - ACUSTOMER PROVIDED 12V BA TTER Y CO NNECTIO N GND1 RED FS LOS GND2 GND3 R1 BCR GND5 R2 GND4 BH1A BH1 COMPAR TMENT CONTROL PANE L JUMPER T3
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