GermGuardian 4270 - Manuals
GermGuardian 4270 – Manual in PDF format online.
Manuals:
Manual GermGuardian 4270
Summary
Table of Contents Page 1 SAFETY ............................ INSIDE FRONT COVER SECTION 1: GENERATOR FUNDAMENTALS ...................... 3-7 MAGNETISM ................................................................ 3ELECTROMAGNETIC FIELDS .................................... 3ELECTROMAGNETIC INDUCT...
Section 1 GENERATOR FUNDAMENTALS MAGNETISM Magnetism can be used to produce electricity andelectricity can be used to produce magnetism.Much about magnetism cannot be explained by ourpresent knowledge. However, there are certain pat-terns of behavior that are known. Application of thesebehavior patt...
Section 1GENERATOR FUNDAMENTALS A SIMPLE AC GENERATOR Figure 1-4 shows a very simple AC Generator. Thegenerator consists of a rotating magnetic field calleda ROTOR and a stationary coil of wire called a STA-TOR. The ROTOR is a permanent magnet which con-sists of a SOUTH magnetic pole and a NORTH mag...
Section 1GENERATOR FUNDAMENTALS FIELD BOOST W h e n t h e e n g i n e i s c r a n k e d d u r i n g s t a r t u p , t h eengine control circuit board Terminals 9, 10, and 11(Wire 14) are energized with 12 VDC. Connected to aWire 14 is a resistor (R2) and a diode (D2). Batterycurrent flows through th...
Section 2 MAJOR GENERATOR COMPONENTS 3. Two excitation winding output leads (No. 2 and 6). These leads deliver unregulated excitation current to the voltage regulator. 4. Three (3) battery charge output leads (No. 55, 66 and 77). Figure 2-2. – Stator Output Leads BRUSH HOLDER The brush holder is ret...
Section 2MAJOR GENERATOR COMPONENTS Figure 2-6. – Excitation Circuit Breaker VOLTAGE REGULATOR:Six (6) leads are connected to the voltage regulatoras follows:• Two (2) SENSING leads deliver ACTUAL AC out- put voltage signals to the regulator. These areWires No. 11 and 22. • Two (2) leads (4 and 1) d...
Section 3 INSULATION RESISTANCE TESTS DANGER!: DO NOT ATTEMPT TO WORKWITH SOLVENTS IN ANY ENCLOSED AREA.PROVIDE ADEQUATE VENTILATION WHENWORKING WITH SOLVENTS. WITHOUT ADE-QUATE VENTILATION, FIRE, EXPLOSION ORHEALTH HAZARDS MAY EXIST . WEAR EYEPROTECTION. WEAR RUBBER GLOVES TOPROTECT THE HANDS. CLOT...
Section 3INSULATION RESISTANCE TESTS a. Across Wires No. 33 and 2. b. Across Wires No. 11 (POWER) and 66. c. Across Wires No. 33 and 66. d. Across Wires No. 2 and 66. If a breakdown in the insulation between isolatedwindings is indicated, clean and dry the Stator. Then,repeat the test. If the Stator...
Section 4MEASURING ELECTRICITY MEASURING AC FREQUENCY The generator's AC output frequency is proportionalto Rotor speed. Generators equipped with a 2-poleRotor must operate at 3600 rpm to supply a frequen-cy of 60-Hertz.Correct engine and Rotor speed is maintained by anengine speed governor. For mod...
Section 4 MEASURING ELECTRICITY ELECTRICAL UNITS AMPERE:The rate of electron flow in a circuit is represented bythe AMPERE. The ampere is the number of electronsf l o w i n g p a s t a g i v e n p o i n t a t a g i v e n t i m e . O n eAMPERE is equal to just slightly more than six thou-sand million...
Section 5ENGINE DC CONTROL SYSTEM ENGINE CONTROL CIRCUIT BOARD GENERAL:The ENGINE CONTROL circuit board is responsiblefor cranking, startup, running, and shutdown opera-tions. The board interconnects with other componentsof the DC control system to turn them on and off atthe proper times. It is powe...
Section 5 ENGINE DC CONTROL SYSTEM battery and starter should not exceed 0.12 VDC per100 amperes of cranking current.Select the battery cables based on total cable lengthand prevailing ambient temperature. Generally, thelonger the cable and the colder the weather, the larg-er the required cable diam...
Section 5ENGINE DC CONTROL SYSTEM 14 AMP FUSE This panel-mounted Fuse protects the DC control cir-cuit against overload and possible damage. If theFuse has melted open due to an overload, neither thepriming function nor the cranking function will beavailable. Figure5-4 PREHEAT SWITCH The diesel engi...
Section 5ENGINE DC CONTROL SYSTEM Figure 5-11. – Glow Plug ENGINE PROTECTIVE DEVICES The engine will shut down automatically in the eventof anyone or more of the following occurrences: • Low oil• High engine coolant temperature• Engine overspeed LOW OIL PRESSURE SWITCH The oil pressure switch has no...
line voltage should read between 242-252 VAC. If voltage andfrequency are good, no adjustment is needed. If voltage andfrequency are low or high, proceed to next step. 4. Turn the governor adjusting screws to obtain a no-load frequen- cy as close as possible to 62-63 HERTZ. With no-load frequen-cy s...
Section 7 DIAGNOSTIC TESTS Page 39 TEST 4 RESULTS A B C D E F G VOLTAGE RESULTS ABOVE ABOVE BELOW ZERO OR BELOW BELOW ABOVE WIRE 2 & 6 60 VAC 60 VAC 60 VAC RESIDUAL 60 VAC 60 VAC 60 VAC EXCITATION WINDING VOLTAGE (5-12 VAC) VOLTAGE RESULTS ABOVE BELOW ABOVE ZERO OR BELOW BELOW ABOVE WIRE 11 &...
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 voltage is measured, it can beassumed that the Field Boost is working. Stop testing. If volt-age is not measured, proceed to Step 4. 4. Test D2 diod...
Section 7 DIAGNOSTIC TESTS Page 41 TEST 8- CHECK SENSING LEADS / POWER WINDINGS DISCUSSION:The Voltage Regulator “regulates” excitation currentflow to the Rotor by electronically comparing sensingvoltage to a pre-set reference voltage. The sensingvoltage is delivered to the Voltage Regulator viaWire...
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 replace any defective wire(s). 2. If wires check good, go to Test 10. Figure 7-6. – Brush Leads TEST 10 - CHECK BRUSHES & SLIP RINGS DISCUSSION:Brushe...
approximately 0.8 Amps. Apply full load to the generator. Theamp reading should increase to approximately 2 Amps. RESULTS: 1. If amperage was measured between 0.8 to 2 Amps in Step 2 and Step 3, the charging system is working. 2. If no amperage was measured, check the VOM fuses and veri- fy the func...
Section 7 DIAGNOSTIC TESTS Page 45 * Resistance values in ohms at 20° C. (68° F.). Actual readingsmay vary depending on ambient temperature. A tolerance ofplus or minus 5% is allowed. RESULTS: 1. For Steps 2 & 3, keep in mind that the resistance values are very low. Depending upon the quality of...
Section 7 DIAGNOSTIC TESTS b. Open armature (wire broken) will be indicated by low or no RPM and excessive current draw. c. Grounded armature (wire insulation worn and wire touching armature lamination or shaft). Willbe indicated by excessive current draw or noRPM. 3. A defective Starter Motor switc...
Section 7DIAGNOSTIC TESTS 8. Crank engine again and see if fuel is coming out of the fuel lines. RESULTS: 1. If no fuel is noted in Steps 3 or 8, replace fuel injector pump. (Reinstallation of all original shims will be required.) 2. If fuel is noted, proceed to next step in flowchart. TEST 37 - CHE...
Section 8ASSEMBLY 4. Attach a hoist hook to the top lifting bracket attached to the engine. 5. Slightly lift the engine to take pressure off of the block of wood. 6. Remove the bolts holding front cross member frame to the engine. STARTER REMOVAL:T o g e t a c c e s s t o t h e s t a r t e r f o r e...
Section 8 ASSEMBLY Figure 8-5. – Applying Tension to Drive Belt Tensioner Figure 8-6. – Position of Drive Belt Tensioner FAN BELT: 1. Install fan belt tensioner as shown in Figure 8-7. Snug mount- ing bolt but do not tighten. 2. Using a small bubble level, verify that tensioner is level hori- zontal...
Section 9 Exploded Views / Part Numbers Page 61 ITEM QTY. DESCRIPTION 1 1 Bearing Carrier, Front 2 1 Bearing Carrier, Upper 3 1 Rotor Assembly 4 1 Stator Assembly 5 1 Ball Bearing 6 1 Ball Bearing 7 1 Brush Holder 8 2 Taptite M5-0.8 x 16mm 9 4 Bolt , Stator 10 6 5/16 Special Lock Washer 11 1 Lug, Li...
Section 9Exploded Views / Part Numbers Page 68 19 17 16 5 14 11 15 28 27 25 26 6 1 2 2 20 1 4 7 25 2 6 27 28 13 2 8 8 18 3 3 3 2 27 29 31 11 Electrical Enclosure Assembly – Drawing No. 0D2361-E
Section 9Exploded Views / Part Numbers Page 70 22 8 22 3 7 1 10 28 4 11 12 5 2 6 9 15 14 16 13 17 16 15 19 20 21 15 15 24 23 8 9 15 16 19 6 9 27 26 TO ENGINE AIR INTAKE 25 Intake and Exhaust System – Drawing No. 0D2362-B
Page 72 Section 9Exploded Views / Part Numbers 10 TO S TARTER M O T O R 16 26 TO G L O W PL UGS 1 7 17 16 10 8 25 13 17 4 26 12 4 19 20 MO T O R B O LT TO S TARTER 6 29 23 9 4 7 21 16 18 14 27 12 15 25 2 3 9 22 24 2 28 4 5 1 2 12 27 TO S TAT O R 7 11 TO G R OU ND 4 Fuel and Electrical Systems – Draw...
Page 73 Section 9 Exploded Views / Part Numbers ITEM QTY. DESCRIPTION 1 1 Fuel Pump Assembly 2 3 1/8 NPT x 5/16 Barbed Straight Fitting 3 2 Bulkhead Adaptor Fitting 4 7 Washer, Split Lk- ¼ -M6 5 1 HHCS M6-1.00 x 30 6 2 Relay Solenoid 7 5 Nut, Hex M6-1 8 1 Clamp, Vinyl Coat 1-1/16" 9 5 Washer, Fl...
Page 74 Section 9Exploded Views / Part Numbers 25 22 28 3 1 15 2 22 26 16 27 30 11 12 3 2 29 33 7 19 13 21 2 6 21 23 24 5 17 18 10 3 6 9 4 8 1 3 4 Customer Controls Assembly – Drawing No. 0D2364-D
Page 81 Section 9 Exploded Views / Part Numbers 12 2 8 10 4 5 11 6 7 9 1.0 Liter Diesel Rocker Arm Assembly – Drawing No. 075683 ITEM QTY. DESCRIPTION 1 1 ROCKER ARM ASSEMBLY(INCLUDES ALL COMPONENTS SHOWN BELOW) 2 3 INTAKE ROCKER ARM 3 3 EXHAUST ROCKER ARM 4 6 NUT 5 6 STUD 6 3 ROCKER ARM BRACKET 7 1...
Page 83 Section 9 Exploded Views / Part Numbers To Injection Pump (Model 04270 & 04614) Tank (Return) 11 To Fuel 1 19 7 18 To Fuel Pump 2 5 3 6 5 18 16 15 16 16 13 14 17 10 14 17 4 5 14 9 10 6 8 1.0 Liter Diesel Fuel Supply – Drawing No. 075693-C ITEM QTY. DESCRIPTION 1 1 FUEL FILTER SUPPORT 2 1...
Page 87 12 11 9 6 5 8 7 4 1 2 3 15 10 1.0 Liter Diesel Water Pump – Drawing No. 082962 ITEM QTY. DESCRIPTION 1 1 WATER PUMP ASSEMBLY 2 1 PLUG 3 1 THERMOSTAT 4 1 SPRING 5 3 GASKET 6 1 SET PLATE 7 1 BOLT 8 1 GASKET 9 1 BOLT 10 1 BOLT 11 1 NUT 12 1 PULLEY 15 1 BOLT Section 9 Exploded Views / Part Numbe...
Section 10SPECIFICATIONS & CHARTS Page 88 24 [.9 4" ] 595. 0 [ 23. 43" ] 60 4 [ 23. 78 "] OVER SCREWS 91 7. 5 [ 3 6 .12 " ] 1. 0 [. 03 929 [ 3 6. 57" ] OVER SCREWS O I L DIP S T IC K O I L F ILL STOP/START S W I T CH CI R C UI T BR E A KE R HOUR METE R FUS E ( 1 4 AMP) COO L ...
Section 10SPECIFICATIONS & CHARTS Page 90 TORQUE SPECIFICATIONS Starter 75 in-lbs. Flywheel 16.2-19 ft-lbs. Rotor Pulley 34.2-41.8 ft-lbs. Stator Bolts 16.2-19.8 ft-lbs. Tension Bolt 44.1-53.9 ft-lbs. Pulley Tension 44.1-53.9 ft-lbs. Weld Stud Nut 32.4-39.6 ft-lbs. Injector Nozzles 58-61 ft-lbs....
Section 11 ELECTRICAL DATA Page 93 14 16 14 0 14 0 56 1 5 0 0 13 0 0 0 15 7 0 56 1 5 0 1 3 1 5 0 14 14 1 7 11 85 14 22 18 11 15 14 11 0 0 1 1 7 11 1 8 1 1 15 0 0 1 0 15 0 13 0 17 18 0 22 66 22 44 55 4 1 11 55 2 6 11 4 14 15 14 44 22 14 66 1 5 44 22 14 1 5 0 1 5 44 22 16 2 16 2 11 0 2 18 17 1 7 14 1 ...
GermGuardian Manuals
-
GermGuardian SCR 11
Manual
-
GermGuardian RS-232
Manual
-
GermGuardian 5659
Manual
-
GermGuardian 5635
Manual
-
GermGuardian 004270-3
Manual
-
GermGuardian 4583
Manual
-
GermGuardian CIT-40
Manual
-
GermGuardian 04758-2, 04759-2, 04760-2
Manual
-
GermGuardian ACT1000
Manual
-
GermGuardian 005336-1, 005337-1
Manual
-
GermGuardian 005244
Manual
-
GermGuardian 004708-0
Manual
-
GermGuardian 5209
Manual
-
GermGuardian GGH200
Manual
-
GermGuardian 004725-0
Manual
-
GermGuardian 005282
Manual
-
GermGuardian R2000
Manual
-
GermGuardian 5656
Manual
-
GermGuardian QT060
Manual
-
GermGuardian H4500
Manual