Guardian-technologies 4270 Manuale Utente

DIAGNOSTIC REPAIR MANUALDIAGNOSTIC REPAIR MANUALQUIETPACT®75DRECREATIONAL VEHICLE GENERATORMODEL 4270

Section 2MAJOR GENERATOR COMPONENTS ROTOR ASSEMBLYThe Rotor is sometimes called the “revolving field”,since it provides the magnetic field that induce

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Section 2MAJOR GENERATOR COMPONENTS3. Two excitation winding output leads (No. 2 and 6). These leadsdeliver unregulated excitation current to the volt

Section 2MAJOR GENERATOR COMPONENTS Figure 2-6. – Excitation Circuit BreakerVOLTAGE REGULATOR:Six (6) leads are connected to the voltage regulatoras f

Section 2MAJOR GENERATOR COMPONENTS Page 11CONTROL PANEL COMPONENT IDENTIFICATIONFigure 2-9. – Control Panel Components

Section 3INSULATION RESISTANCE TESTSEFFECTS OF DIRT AND MOISTUREMoisture and dirt are harmful to the continued goodoperation of any generator set.If m

Section 3INSULATION RESISTANCE TESTSDANGER!: DO NOT ATTEMPT TO WORKWITH SOLVENTS IN ANY ENCLOSED AREA.PROVIDE ADEQUATE VENTILATION WHENWORKING WITH SO

Section 3INSULATION RESISTANCE TESTSa. Across Wires No. 33 and 2.b. Across Wires No. 11 (POWER) and 66.c. Across Wires No. 33 and 66.d. Across Wires N

Section 4MEASURING ELECTRICITYMETERSDevices used to measure electrical properties arecalled meters. Meters are available that allow one tomeasure (a)

Section 4MEASURING ELECTRICITYMEASURING AC FREQUENCYThe generator's AC output frequency is proportionalto Rotor speed. Generators equipped with a

Section 4MEASURING ELECTRICITYELECTRICAL UNITSAMPERE:The rate of electron flow in a circuit is represented bythe AMPERE. The ampere is the number of e

SAFETYThroughout this publication, "DANGER!" and "CAUTION!" blocks are used to alert the mechanic for specialinstructions concerni

Section 5ENGINE DC CONTROL SYSTEMINTRODUCTIONThe engine DC control system includes all compo-nents necessary for the operation of the engine.Operation

Section 5ENGINE DC CONTROL SYSTEMPage 19CIRCUIT CONDITION- PRE-HEAT:When the PRE-HEAT SWITCH (SW) or theREMOTE PANEL PRE-HEAT SWITCH is closed bythe o

Section 5ENGINE DC CONTROL SYSTEMPage 20CIRCUIT CONDITION- CRANKING:When the START-STOP-SWITCH (SW1) or REMOTEPANEL START-STOP-SWITCH is held at "

Section 5ENGINE DC CONTROL SYSTEMPage 21CIRCUIT CONDITION-RUNNING:With the FUEL PUMP (FP) and FUEL SOLENOID(FS) operating the engine should start. The

Section 5ENGINE DC CONTROL SYSTEMPage 22CIRCUIT CONDITION- SHUTDOWN:Setting the START-STOP SWITCH (SW1) or theREMOTE PANEL START-STOP SWITCH to its&qu

Section 5ENGINE DC CONTROL SYSTEMPage 23CIRCUIT CONDITION- FAULT SHUTDOWNS:The engine has mounted to it a HIGH WATER TEM-PERATURE SWITCH (HWT) and a L

Section 5ENGINE DC CONTROL SYSTEMENGINE CONTROL CIRCUIT BOARDGENERAL:The ENGINE CONTROL circuit board is responsiblefor cranking, startup, running, an

Section 5ENGINE DC CONTROL SYSTEMbattery and starter should not exceed 0.12 VDC per100 amperes of cranking current.Select the battery cables based on

Section 5ENGINE DC CONTROL SYSTEM14 AMP FUSEThis panel-mounted Fuse protects the DC control cir-cuit against overload and possible damage. If theFuse

Section 5ENGINE DC CONTROL SYSTEMThe positive (+) battery cable (13) attaches to one ofthe outer posts of the contactor along with Wire 13 forthe DC s

Table of ContentsPage 1SAFETY ... INSIDE FRONT COVERSECTION 1: GENERATOR FUNDAMENTALS ... 3-7MAGNETISM ...

Section 5ENGINE DC CONTROL SYSTEMFigure 5-11. – Glow PlugENGINE PROTECTIVE DEVICESThe engine will shut down automatically in the eventof anyone or mor

Section 6TROUBLESHOOTING FLOWCHARTSThe “Flow Charts” in this section can be used in con-junction with the “Diagnostic Tests” of Section 7.Numbered tes

Section 6TROUBLESHOOTING FLOWCHARTSPage 30

Section 6TROUBLESHOOTING FLOWCHARTSPage 31TEST 4 -PERFORM FIXEDEXCITATION /ROTOR AMPDRAWTEST 7 - TESTSTATOR DPEWINDINGCHECK VOM FUSES -VERIFY AMP METE

Section 6TROUBLESHOOTING FLOWCHARTSPage 32

Section 6TROUBLESHOOTING FLOWCHARTSPage 33

Section 6TROUBLESHOOTING FLOWCHARTSPage 34

Section 6TROUBLESHOOTING FLOWCHARTSPage 35

Section 6TROUBLESHOOTING FLOWCHARTSPage 36

Section 7DIAGNOSTIC TESTSPage 37INTRODUCTIONThe “Diagnostic Tests” in this chapter may be per-formed in conjunction with the “Flow Charts” ofSection 6

TEST 10 - Check Brushes & Slip Rings ... 42TEST 11 - Check Rotor Assembly...

line voltage should read between 242-252 VAC. If voltage andfrequency are good, no adjustment is needed. If voltage andfrequency are low or high, pr

Section 7DIAGNOSTIC TESTSPage 39TEST 4 RESULTSABCDEFGVOLTAGE RESULTS ABOVE ABOVE BELOW ZERO OR BELOW BELOW ABOVEWIRE 2 & 6 60 VAC 60 VAC 60 VAC RE

3. Set the Start-Stop Switch to “START.” During cranking only,measure DC voltage. It should read 3-5 VDC. Reconnect Wire4 to the Voltage Regulator. If

Section 7DIAGNOSTIC TESTSPage 41TEST 8- CHECK SENSING LEADS / POWERWINDINGSDISCUSSION:The Voltage Regulator “regulates” excitation currentflow to the

one meter test lead to Wire 1. Connect the other test lead to aclean ground. The meter should read “Continuity”.RESULTS:1. Repair, reconnect or replac

Section 7DIAGNOSTIC TESTSPage 43RESULTS:1. Replace the Rotor if it fails the test. 2. If Rotor checks good, perform “Insulation Resistance Test,” onPa

approximately 0.8 Amps. Apply full load to the generator. Theamp reading should increase to approximately 2 Amps.RESULTS:1. If amperage was measured b

Section 7DIAGNOSTIC TESTSPage 45* Resistance values in ohms at 20° C. (68° F.). Actual readingsmay vary depending on ambient temperature. A tolerance

Section 7DIAGNOSTIC TESTSPage 46PROCEDURE:1. Set a VOM to measure DC voltage.2. Disconnect the connector from the wires of the fuel pump.3. Place the

3. Set the VOM to measure resistance (“Rx1” scale). Connectone meter test lead to Wire 0, Terminal 2 on the EngineController Circuit Board. Connect th

Section 1GENERATOR FUNDAMENTALSMAGNETISMMagnetism can be used to produce electricity andelectricity can be used to produce magnetism.Much about magnet

Section 7DIAGNOSTIC TESTSRESULTS:1. If “Continuity” is not measured in Step 2, repair, reconnect orreplace Wire 0 (between Start-Stop Switch and groun

Section 7DIAGNOSTIC TESTSb.Open armature (wire broken) will be indicatedby low or no RPM and excessive current draw.c.Grounded armature (wire insulati

Section 7DIAGNOSTIC TESTSFigure 7-16. – Clamp-On AmmeterTACHOMETER:A tachometer is available from your Generac PowerSystems source of supply. Order as

Section 7DIAGNOSTIC TESTSTEST 28- CHECK FUEL SUPPLYDISCUSSION:If the engine cranks but won't start, don't overlook theobvious. The fuel sup

Section 7DIAGNOSTIC TESTS6. Place test leads on each end of wire, continuity should bemeasured.7. If continuity is measured, test battery voltage on W

Section 7DIAGNOSTIC TESTSTEST 35- CHECK VALVE ADJUSTMENTDISCUSSION:If the engine is having a hard start, no start, or roughrunning condition, then the

Section 7DIAGNOSTIC TESTS8. Crank engine again and see if fuel is coming out of the fuellines.RESULTS:1. If no fuel is noted in Steps 3 or 8, replace

Section 7DIAGNOSTIC TESTSNOTE: For units out of warranty, refer toQuicksilver Diagnostic & Service Manual - Diesel,P/N 082034 for further engine s

Section 7DIAGNOSTIC TESTSRESULTS:1. If continuity is measure, replace the switch.2. If infinity is measured, proceed to next test on the flow chart.TE

Section 8ASSEMBLYMAJOR DISASSEMBLYENCLOSURE/ PANEL REMOVAL:Using a 10-mm socket, remove all screws on all pan-els except the lower screws on the radia

Section 1GENERATOR FUNDAMENTALSA SIMPLE AC GENERATORFigure 1-4 shows a very simple AC Generator. Thegenerator consists of a rotating magnetic field ca

Section 8ASSEMBLY4. Attach a hoist hook to the top lifting bracket attached to theengine.5. Slightly lift the engine to take pressure off of the block

Section 8ASSEMBLYFigure 8-5. – Applying Tension to Drive BeltTensionerFigure 8-6. – Position of Drive Belt TensionerFAN BELT:1. Install fan belt tensi

Section 9Exploded Views / Part NumbersPage 60264645424122251403837362117262623325492281344495041128729193110914182432252733352122202139214339Engine, A

Section 9Exploded Views / Part NumbersPage 61ITEM QTY. DESCRIPTION1 1 Bearing Carrier, Front2 1 Bearing Carrier, Upper3 1 Rotor Assembly4 1 Stator Ass

Section 9Exploded Views / Part NumbersPage 62134210981211131416171817211915222320675134717Base Frame – Drawing No. 0D2357-A

Section 9Exploded Views / Part NumbersPage 63ITEM QTY. DESCRIPTION1 1 Base Frame Weldment2 1 Door, Service Rear3 1 Door, Service Front4 4 Slide Latch

Section 9Exploded Views / Part NumbersPage 6438363717241715351434211726VIEW"A"18176417313211283010A2217192933271713201217168523217257317192E

Section 9Exploded Views / Part NumbersPage 65ITEM QTY. DESCRIPTION1 1 Enclosure Panel RH2 1 Enclosure Panel Top3 1 Enclosure Panel LH4 1 Enclosure Pa

Section 9Exploded Views / Part NumbersPage 66531813634302933344840424612252725547424335125444534283150 (RE37382354521193432414412491439211814417203915

Section 9Exploded Views / Part NumbersPage 67ITEM QTY. DESCRIPTION1 1 Cover Plate, Scroll Weldment2 1 Housing, Fan Scroll Weldment3 1 Fan, Squirrel Ca

Section 1GENERATOR FUNDAMENTALSNOTE: AC output frequency at 3720 rpm will beabout 62-Hertz. The “No-Load” is set slightly highto prevent excessive rpm

Section 9Exploded Views / Part NumbersPage 68191716514111528272526612220147252627281328818333227293111Electrical Enclosure Assembly – Drawing No. 0D23

Section 9Exploded Views / Part NumbersITEM QTY. DESCRIPTION1 1 Weldment, Electrical Enclosure2 1 Terminal Block 4 Position3 1 Assembly, Potted Regulat

Section 9Exploded Views / Part NumbersPage 70228223711028411125269151416131716151920211515242389151619692726TO ENGINE AIR INTAKE25Intake and Exhaust S

Section 9Exploded Views / Part NumbersPage 71ITEM QTY. DESCRIPTION1 1 Exhaust Gasket2 1 Chamber Air Intake3 1 Air Filter4 1 Hose, Air Inlet5 1 Muffler

Page 72Section 9Exploded Views / Part Numbers10TO STARTER MOTOR1626TO GLOW PLUGS1717161082513174261241920MOTOR BOLTTO STARTER6292394721161814271215252

Page 73Section 9Exploded Views / Part NumbersITEM QTY. DESCRIPTION1 1 Fuel Pump Assembly2 3 1/8 NPT x 5/16 Barbed Straight Fitting3 2 Bulkhead Adapto

Page 74Section 9Exploded Views / Part Numbers2522283115222261627301112322933719132126212324517181036948134Customer Controls Assembly – Drawing No. 0D2

Page 75Section 9Exploded Views / Part NumbersITEM QTY. DESCRIPTION1 1 Start / Stop Switch2 1 Cover, Engine Control Box3 1 Hour Meter4 1 Fuse Holder, S

Page 76Section 9Exploded Views / Part Numbers1213119831015645271.0 Liter Diesel Camshaft – Drawing No. 075677ITEM QTY. DESCRIPTION1 1 CAMSHAFT ASSEMBL

Page 77Section 9Exploded Views / Part Numbers2952623252413171230378629101122191927281514162014215181.0 Liter Diesel Cylinder Block – Drawing No. 07567

Section 1GENERATOR FUNDAMENTALSFIELD BOOSTWhen the engine is cranked during startup, theengine control circuit board Terminals 9, 10, and 11(Wire 14)

Page 78Section 9Exploded Views / Part Numbers34211192131108714421965171620221218231.0 Liter Diesel Cylinder Head – Drawing No. 0D2794ITEM QTY. DESCRIP

Page 79Section 9Exploded Views / Part Numbers2019181617283032417221962111101214910111595131.0 Liter Diesel Crankshaft, Piston and Flywheel – Drawing N

Page 80Section 9Exploded Views / Part Numbers5123248679111101.0 Liter Diesel Oil Pump – Drawing No. 75682ITEM QTY. DESCRIPTION1 1 IDLER GEAR ASSEMBLY2

Page 81Section 9Exploded Views / Part Numbers123281045116791.0 Liter Diesel Rocker Arm Assembly – Drawing No. 075683ITEM QTY. DESCRIPTION1 1 ROCKER AR

Page 82Section 9Exploded Views / Part Numbers1141413121216& 04614 ONLY)(MODEL 04270 8191926292833201710187627591.0 Liter Diesel Injector Pump – Dr

Page 83Section 9Exploded Views / Part NumbersTo Injection Pump(Model 04270 & 04614)Tank (Return)11To Fuel 119718To Fuel Pump2536518161516161314171

Page 84Section 9Exploded Views / Part Numbers3454447434244049504842363713538132529302733323126283445261232422(Model 04270 & 04614)5152818193946151

Page 85Section 9Exploded Views / Part NumbersITEM QTY. DESCRIPTION1 1 HOUSING, TIMING GEAR2 1 SPRING PIN3 1 GASKET4 1 SPRING5 1 WASHER6 2 NUT7 1 STOP

Page 86Section 9Exploded Views / Part Numbers33172814121524252322113218313014192014291.0 Liter Diesel Engine Block – Drawing No. 082961-CITEM QTY. DES

Page 87121196587412315101.0 Liter Diesel Water Pump – Drawing No. 082962ITEM QTY. DESCRIPTION1 1 WATER PUMP ASSEMBLY2 1 PLUG3 1 THERMOSTAT4 1 SPRING5

Section 1GENERATOR FUNDAMENTALSReroute stator lead 44 from the line side terminal of CB1(renamed as CB1A in Figure 1-9) to the ground stud locationpre

Section 10SPECIFICATIONS & CHARTSPage 8824[.94"]595.0 [23.43"]604 [23.78 "]OVER SCREWS917.5 [3 6.12 " ]1.0[.03929 [36.57"

Section 10SPECIFICATIONS & CHARTSPage 89Type of Engine ISM DieselCylinder Arrangement 3, in-lineDisplacement 58.2 in3. (954 cc)Bore 2.95 in. (75 m

Section 10SPECIFICATIONS & CHARTSPage 90TORQUE SPECIFICATIONSStarter 75 in-lbs.Flywheel 16.2-19 ft-lbs.Rotor Pulley 34.2-41.8 ft-lbs.Stator Bolts

NOTESPage 91

Section 11ELECTRICAL DATAPage 92T122151514464T2T2T36416 2244 A11A11A44 A11A44 A11221155661313131414015 0440141515 01515 015131514141314085145614561444

Section 11ELECTRICAL DATAPage 9314161401405615 001300015 70561501315 01414171185142218111514110011711181115 001015 01301718022662244554111552611414151

Page 94Section 11ELECTRICAL DATASW1 -SWITCH, START/STOPF1 - FU SE 14A M P S FED1 - DIOD E 600V , 6A M PB CW - B ATT ERY CHAR GERSC -START CO N TACTORS

Page 95Section 11ELECTRICAL DATASW1 -SWITCH, START/STOPF1 - FU SE 14A M P S FED1 - DIOD E 600V , 6A M PB CW - B ATT ERY CHAR G ERSC -START CO N TACTOR

Page 96Section 11ELECTRICAL DATAWIRE DIAGRAM, 1.0L DSLSINGLE 120/240VAC OUTPUTC4946-A671212117HWTLOSGLOW P LUG SSW 2D1FPFSSW 1CB 1GND6R1GND1F1GND4GND

Page 97Section 11ELECTRICAL DATAWIRE DIAGRAM, 1.0L DSLDUAL 120VAC, 35A OUTPUTC4946-A67121011112SHEET 2 OF 2CUSTOMER PROVIDED12V BA TTER Y CO NN ECTIO