Guardian 4700 - User Manual

Manual Part No. 0E1881
DIAGNOSTIC
REPAIR
MANUAL
RECREATIONAL VEHICLE GENERATOR
Model 4700
QUIETPACT
®
40
P.O. Box 297 • Whitewater, WI 53190
Phone: (262) 473-5514 Fax: (262) 472-6505
Printed in U.S.A Revision A - 10/13/03
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Summary

Section 1 GENERATOR FUNDAMENTALS

MAGNETISM

Basic principles of magnetism and its role in electrical generation.

ELECTROMAGNETIC FIELDS

How electric currents create magnetic fields and their properties.

ELECTROMAGNETIC INDUCTION

The process of generating voltage by moving conductors through magnetic fields.

A SIMPLE AC GENERATOR

Explanation of a basic AC generator design and operation.

A MORE SOPHISTICATED AC GENERATOR

Details of a generator with regulated output using brushes and slip rings.

FIELD BOOST

How field boost current aids in starting and building output voltage.

GENERATOR AC CONNECTION SYSTEM

How the generator's AC power windings are connected for output.

Section 2 MAJOR GENERATOR COMPONENTS

ROTOR ASSEMBLY

Description of the revolving field component that creates the magnetic field.

STATOR ASSEMBLY

Description of the stationary component containing the windings for power generation.

BRUSH HOLDER

Component that holds brushes to make contact with slip rings.

BATTERY CHARGE COMPONENTS

Components responsible for charging the unit's battery.

EXCITATION CIRCUIT COMPONENTS

Components involved in providing current to the rotor for excitation.

BREATHER ASSEMBLY

Component that maintains crankcase pressure and vents vapors.

Section 3 INSULATION RESISTANCE TESTS

EFFECTS OF DIRT AND MOISTURE

How contaminants affect generator insulation resistance and performance.

INSULATION RESISTANCE TESTERS

Introduction to tools used for testing winding insulation integrity.

DRYING THE GENERATOR

Procedures for drying a generator to improve insulation resistance.

CLEANING THE GENERATOR

Methods for cleaning generator components to maintain performance.

STATOR INSULATION RESISTANCE

Detailed procedures for testing stator winding insulation resistance.

TESTING ROTOR INSULATION

Procedures for testing the insulation resistance of the rotor.

THE MEGOHMMETER

Explanation of how to use a megohmmeter for insulation testing.

Section 4 MEASURING ELECTRICITY

METERS

Overview of various meters used for electrical measurements.

THE VOM

Explanation of the Volt-Ohm-Milliammeter (VOM) and its usage.

MEASURING AC VOLTAGE

Procedures for accurately measuring AC voltage output from the generator.

MEASURING DC VOLTAGE

Guidelines for measuring DC voltage, including polarity and scale selection.

MEASURING AC FREQUENCY

How to measure the generator's AC output frequency in Hertz.

MEASURING CURRENT

Methods for measuring electrical current flow using clamp-on ammeters.

MEASURING RESISTANCE

Techniques for measuring resistance in generator windings and circuits.

ELECTRICAL UNITS

Definitions of fundamental electrical units like Ampere, Volt, and Ohm.

OHMS LAW

Explanation and application of Ohm's Law for electrical calculations.

Section 5 ENGINE DC CONTROL SYSTEM

INTRODUCTION

Overview of the DC control system and its functions.

OPERATIONAL ANALYSIS

Step-by-step breakdown of the engine's operational states.

ENGINE CONTROLLER CIRCUIT BOARD

Description of the engine controller's role and connections.

7.5 AMP FUSE

Information about the 7.5 amp fuse protecting the DC control circuit.

FUEL PRIMER SWITCH

Function and operation of the fuel primer switch for priming the fuel system.

START-STOP SWITCH

How the start-stop switch controls engine cranking, startup, and shutdown.

STARTER CONTACTOR & MOTOR

Explanation of the starter contactor and motor's role in engine cranking.

Section 6 TROUBLESHOOTING FLOWCHARTS

PROBLEM 1 - VOLTAGE & FREQUENCY ARE BOTH HIGH OR LOW

Flowchart for diagnosing high or low voltage/frequency issues.

PROBLEM 2 - GENERATOR PRODUCES ZERO VOLTAGE OR RESIDUAL VOLTAGE (5-12 VAC)

Flowchart for troubleshooting zero or low residual voltage output.

PROBLEM 3 - NO BATTERY CHARGE OUTPUT

Flowchart for diagnosing issues with the battery charging system.

PROBLEM 4 - EXCESSIVE VOLTAGE;FREQUENCY DROOP WHEN LOAD IS APPLIED

Flowchart for troubleshooting voltage/frequency drop under load.

PROBLEM 5 - PRIMING FUNCTION DOES NOT WORK

Flowchart for diagnosing a non-functional priming function.

PROBLEM 6 - ENGINE WILL NOT CRANK

Flowchart for troubleshooting an engine that fails to crank.

PROBLEM 7 - ENGINE CRANKS BUT WILL NOT START

Flowchart for diagnosing an engine that cranks but won't start.

PROBLEM 8 - ENGINE STARTS HARD AND RUNS ROUGH

Flowchart for troubleshooting rough engine starting and running.

PROBLEM 9 - ENGINE STARTS THEN SHUTS DOWN

Flowchart for diagnosing an engine that starts and then shuts down.

PROBLEM 10 - 7.5 AMP (F1) FUSE BLOWING

Flowchart for troubleshooting a blowing 7.5 amp fuse.

Section 7 DIAGNOSTIC TESTS

TEST 1- CHECK NO-LOAD VOLTAGE AND FREQUENCY

Procedure to check generator output voltage and frequency at no-load.

TEST 2- CHECK ENGINE GOVERNOR

Procedure to check and adjust the engine governor for correct speed.

TEST 3- TEST EXCITATION CIRCUIT BREAKER

Procedure to test the excitation circuit breaker for proper operation.

TEST 4- FIXED EXCITATION TEST;ROTOR AMP DRAW

Procedure to test the fixed excitation circuit and rotor amp draw.

TEST 5- WIRE CONTINUITY

Procedure to check the continuity of critical wires in the excitation circuit.

TEST 6- CHECK FIELD BOOST

Procedure to verify the operation of the field boost circuit.

TEST 7 - TEST STATOR DPE WINDING

Procedure to test the Stator DPE (excitation) winding resistance and shorts.

TEST 8- CHECK SENSING LEADS;POWER WINDINGS

Procedure to check sensing leads and stator power windings for continuity and shorts.

TEST 9 - CHECK BRUSH LEADS

Procedure to check the brush leads for continuity.

TEST 10 - CHECK BRUSHES & SLIP RINGS

Procedure to inspect and clean brushes and slip rings.

TEST 11 - CHECK ROTOR ASSEMBLY

Procedure to test the rotor assembly for continuity and shorts.

TEST 12 - CHECK MAIN CIRCUIT BREAKER

Procedure to check the main circuit breaker for continuity.

TEST 13- CHECK LOAD VOLTAGE & FREQUENCY

Procedure to check voltage and frequency under electrical load.

TEST 14- CHECK LOADWATTS & AMPERAGE

Procedure to check if the load exceeds the generator's capacity.

TEST 18 - TRY CRANKING THE ENGINE

Procedure to attempt cranking the engine to check basic operation.

TEST 15 - CHECK BATTERY CHARGE OUTPUT

Procedure to check the DC output current for battery charging.

TEST 16 - CHECK BATTERY CHARGE RECTIFIER

Procedure to test the battery charge rectifier for proper diode function.

TEST 17 - CHECK BATTERY CHARGE WINDINGS; BATTERY CHARGE RESISTOR

Procedure to test battery charge windings and resistor.

TEST 19 - TEST PRIMER SWITCH

Procedure to test the fuel primer switch for proper operation.

TEST 20 - CHECK FUEL PUMP

Procedure to test the fuel pump for operation and coil resistance.

TEST 21 - CHECK 7.5 AMP FUSE

Procedure to check the 7.5 amp fuse for continuity.

TEST 22 - CHECK BATTERY & CABLES

Procedure to check the battery and cables for condition and charge.

TEST 23 - CHECK POWER SUPPLY TO CIRCUIT BOARD

Procedure to verify battery voltage supply to the engine controller board.

TEST 24 - CHECK START-STOP SWITCH

Procedure to test the start-stop switch for proper continuity and function.

TEST 25 - CHECK POWER SUPPLY TO WIRE 56

Procedure to check for battery voltage at Wire 56 for starter engagement.

TEST 26 - CHECK STARTER CONTACTOR

Procedure to test the starter contactor for continuity and proper function.

TEST 27 - CHECK STARTER MOTOR

Procedure to test the starter motor for operation and current draw.

TEST 28 - CHECK FUEL SUPPLY

Procedure to check for adequate and fresh fuel supply to the engine.

TEST 29 - CHECK WIRE 14 POWER SUPPLY

Procedure to check for battery voltage on Wire 14 supplying the fuel pump.

TEST 30 - CHECK WIRE 18

Procedure to check Wire 18 for shorts to ground, related to engine shutdown.

TEST 31 - CHECK FUEL SOLENOID

Procedure to test the fuel solenoid for proper operation and voltage supply.

TEST 32 - CHECK IGNITION SPARK

Procedure to test for proper ignition spark using a spark tester.

TEST 33 - CHECK SPARK PLUG

Procedure to inspect, clean, and gap the spark plug.

TEST 34 - CHECK IGNITION COIL

Procedure to test the ignition coil assembly for proper resistance.

TEST 35 - CHECK VALVE ADJUSTMENT

Procedure for checking and adjusting engine valve clearance.

TEST 36 - CHECK CARBURETION

Procedure to check the carburetor for proper fuel mixture and operation.

TEST 37 - CHECK CHOKE SOLENOID

Procedure to test the automatic choke solenoid's function.

TEST 38 - CHECK ENGINE; CYLINDER LEAK DOWN TEST; COMPRESSION TEST

Procedures for cylinder leak down and compression testing.

TEST 39 - CHECK OIL PRESSURE SWITCH

Procedure to test the low oil pressure switch for proper function.

TEST 40 - TEST OIL TEMPERATURE SWITCH

Procedure to test the oil temperature switch for proper operation.

TEST 41 - TEST CHOKE HEATER

Procedure to test the choke heater element for voltage and resistance.

Section 8 ASSEMBLY

MAJOR DISASSEMBLY

Step-by-step instructions for major disassembly of the generator unit.

ENCLOSURE;PANELS

Procedures for removing the generator's enclosure and panels.

ENGINE REMOVAL

Instructions for safely removing the engine from the generator assembly.

ROTOR;STATOR REMOVAL

Steps for removing the rotor and stator components from the generator.

FLYWHEEL;IGNITION COIL REMOVAL

Instructions for removing the flywheel and ignition coil assembly.

Section 9 SPECIFICATIONS & CHARTS

GENERATOR SPECIFICATIONS

Key technical specifications for the generator model.

TORQUE SPECIFICATIONS

Recommended torque values for various engine and generator fasteners.

NOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68°F

Expected resistance values for generator windings at a specific temperature.

ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS

Specifications for engine speed, voltage, and frequency under different load conditions.

Section 10 ELECTRICAL DATA

ELECTRICAL SCHEMATIC AND WIRING DIAGRAM

Detailed electrical schematic and wiring diagram of the generator system.

Guardian 4700 Specifications

General

Output Voltage	120VAC
Output Frequency	60Hz
Overload Protection	Yes
Thermal Protection	Yes
Cooling	Fan
Efficiency	90%
Weight	6.5 kg