OF4996 REV. O | Guardian Technologies 4270 manual

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

P/N OF4996 REV. O

PRINTED IN THE USA/1.05

Image 100

Guardian Technologies 4270 manual OF4996 REV. O

Contents

Diagnostic Repair Manual Safety Replacement Parts Table of Contents 57-59 Electromagnetic Fields MagnetismElectromagnetic Induction Simple AC Generator More Sophisticated AC Generator Generator 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 Rings Battery Charge Components Brush HolderExcitation Circuit Components General Adjust POT LED Adjustment Procedure162 Voltage Regulator Control Panel Component Identification Control Panel Components Cleaning the Generator Effects of Dirt and MoistureDrying the Generator Insulation Resistance Testers Brushing and Vacuum Cleaning Stator Insulation ResistanceCloth or Compressed AIR Stator SHORT-TO-GROUND Tests Testing Rotor Insulation Megohmmeter Meters VOMMeasuring AC Voltage Measuring DC Voltage Measuring Current Measuring AC FrequencyMeasuring Resistance Electrical Units Ohms LAW Operational 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 Board Effects of Temperature Checking Battery State of ChargeCharging a Battery Adding Water Preheat Switch START/STOP SwitchAMP Fuse Starter Contactor & Motor Engine Governor Fuel Injection PumpFuel NOZZLES/INJECTORS Glow Plugs LOW OIL Pressure Switch High Coolant Temperature Switch Adapter LOW OIL Pressure SwitchEngine Protective Devices Overspeed Protection Troubleshooting 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 Frequency Test 3- Test Excitation Circuit Breaker Test 4- Fixed Excitation TEST/ROTOR AMP Draw Test 5- Wire Continuity Re-connect Wire 11 and Wire 22 to the Voltage RegulatorTest 6- Check Field Boost Set a VOM to its Rx1 scale Test 7 Test Stator DPE Winding Model QP75D Test 8- Check Sensing Leads / Power Windings Test 9- Check Brush Leads159W 184W Tance 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 & Amperage Battery 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 Pump Test 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 Fuse Test 24 Check START-STOP Switch Not Activated Test 27 Check Starter Motor Test 26- Test Starter ContactorConditions Affecting Starter Motor Performance Checking the Pinion PinionTools for Starter Performance Test Measuring Current Testing Starter Motor TachometerTest Bracket Starter motor test bracket may be made as shown in Figure Test 29 Check Wire 14 Power Supply Test 30 Check WireIf Wire 18 checks GOOD, proceed to Problem 8 Section Test 28- Check Fuel Supply Test 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 cylinder Test 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 Tensioning Line Corner UP Between 5˚ to 10˚ FAN Belt Section Exploded Views / Part Numbers Rotor Assembly Stator AssemblyFlywheel Assembly Bearing Carrier, Front Base Frame Drawing No D2357-A Door, Service Rear Door, Service FrontBase Frame Weldment Slide Latch Flush Enclosure 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 Inlet Views / Part Numbers Fuel Pump Assembly Boot, Battery CableCable, Battery Wire Assembly, Black #4 Ground Customer Controls Assembly Drawing No D2364-D Start / Stop Switch Switch, Pushbutton SpstBoot / Nut / Preheat Switch Boot, Circuit Breaker Camshaft Assembly Camshaft GearKEY Gear 2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B Idler Gear Assembly SpringThrust Washer OIL Pump Cover Rocker ARM Assembly Includes ALL Components Shown belowIntake Rocker ARM Exhaust Rocker ARM Liter 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 Specifications ROTOR/STATOR Resistance Values Type Quietpact ModelPage Data Data Electrical Data Schematic Drawing No C4945-A Model C4945 Electrical C4946-A Sheet 2 OF4996 REV. O