Guardian Technologies 4270 Table of Contents, Generator Fundamentals, Troubleshooting Flowcharts

Table of Contents

SAFETY	INSIDE FRONT COVER
SECTION 1:
GENERATOR FUNDAMENTALS		3-7
MAGNETISM		3
ELECTROMAGNETIC FIELDS		3
ELECTROMAGNETIC INDUCTION		3
A SIMPLE AC GENERATOR		4
A MORE SOPHISTICATED AC GENERATOR		4
FIELD BOOST		6
GENERATOR AC CONNECTION SYSTEM		6
SECTION 2:
MAJOR GENERATOR COMPONENTS		8-11
ROTOR ASSEMBLY		8
STATOR ASSEMBLY		8
BRUSH HOLDER		9
BATTERY CHARGE COMPONENTS		9
EXCITATION CIRCUIT COMPONENTS		9
VOLTAGE REGULATOR		10
CONTROL PANEL
COMPONENT IDENTIFICATION		11
SECTION 3:
INSULATION RESISTANCE TESTS		12-14
EFFECTS OF DIRT AND MOISTURE		12
INSULATION RESISTANCE TESTERS		12
DRYING THE GENERATOR		12
CLEANING THE GENERATOR		12
STATOR INSULATION RESISTANCE		13
TESTING ROTOR INSULATION		14
THE MEGOHMMETER		14
SECTION 4:
MEASURING ELECTRICITY		15-17
METERS		15
THE VOM		15
MEASURING AC VOLTAGE		15
MEASURING DC VOLTAGE		15
MEASURING AC FREQUENCY		16
MEASURING CURRENT		16
MEASURING RESISTANCE		16
ELECTRICAL UNITS		17
OHM’S LAW		17
SECTION 5:
ENGINE DC CONTROL SYSTEM		18-28
INTRODUCTION		18
OPERATIONAL ANALYSIS		18-23
ENGINE CONTROLLER CIRCUIT BOARD		24
BATTERY		24
14 AMP FUSE		26
PRE-HEAT SWITCH		26
START-STOP SWITCH		26
STARTER CONTACTOR & MOTOR		26

ENGINE GOVERNOR	27
FUEL INJECTION PUMP	27
FUEL NOZZLES/INJECTORS	27
GLOW PLUGS	27
ENGINE PROTECTIVE DEVICES	28
LOW OIL PRESSURE SWITCH	28
HIGH COOLANT TEMPERATURE SWITCH	28
OVERSPEED PROTECTION	28
SECTION 6:
TROUBLESHOOTING FLOWCHARTS	29-36
IF PROBLEM INVOLVES AC OUTPUT	29
PROBLEM 1 -
VOLTAGE & FREQUENCY ARE BOTH
HIGH OR LOW	29
PROBLEM 2 -
GENERATOR PRODUCES ZERO VOLTAGE OR
RESIDUAL VOLTAGE (5-12 VAC)	30-31
PROBLEM 3 -
NO BATTERY CHARGE OUTPUT	31
PROBLEM 4 -
EXCESSIVE VOLTAGE/FREQUENCY DROOP
WHEN LOAD IS APPLIED	32
PROBLEM 5 -
PRIMING FUNCTION DOES NOT WORK	32
PROBLEM 6 -
ENGINE WILL NOT CRANK	33
PROBLEM 7 -
ENGINE CRANKS BUT WILL NOT START /
RUNS HARD	34
PROBLEM 8 -
ENGINE STARTS THEN SHUTS DOWN	35
PROBLEM 9 -
14 AMP (F1) FUSE BLOWING	36
SECTION 7:
DIAGNOSTIC TESTS	37-57
INTRODUCTION	37
TEST 1 -
Check No-Load Voltage And Frequency	37
TEST 2 -
Check Engine Governor	37-38
TEST 3 -
Test Excitation Circuit Breaker	38
TEST 4 -
Fixed Excitation Test/Rotor Amp Draw	38-39
TEST 5 -
Wire Continuity	39
TEST 6 -
Check Field Boost	39-40
TEST 7 -
Test Stator DPE Winding	40-41
TEST 8 -
Check Sensing Leads/Power Windings	41
TEST 9 -
Check Brush Leads	41-42

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