Guardian Technologies 4270 manual Troubleshooting Flowcharts

Page 31

Section 6

TROUBLESHOOTING FLOWCHARTS

INTRODUCTION

The “Flow Charts” in this section can be used in con- junction with the “Diagnostic Tests” of Section 7. Numbered tests in the Flow Charts correspond to identically numbered tests of Section 7.

Problems 1 through 4 apply to the AC generator only.

Beginning with Problem 5, the engine DC control sys- tem is dealt with.

Page 29

Image 31

Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents 57-59 Electromagnetic Fields MagnetismElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostLine Breakers 120 VAC only Connection for 120/240 VAC Dual Voltage LIC Grit or Abrasive to Clean Slip Rings Rotor AssemblyGeneral Battery Charge ComponentsBrush Holder Excitation Circuit ComponentsVoltage Regulator Adjust POT LEDAdjustment Procedure 162Control Panel Components Control Panel Component IdentificationInsulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the GeneratorStator SHORT-TO-GROUND Tests Brushing and Vacuum CleaningStator Insulation Resistance Cloth or Compressed AIRMegohmmeter Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC VoltageMeasuring Current Measuring AC FrequencyMeasuring Resistance Ohms LAW Electrical UnitsOperational Analysis IntroductionCircuit CONDITION- OFF Circuit CONDITION- PRE-HEAT Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Circuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdowns Engine Control Circuit Board BatteryAdding Water Effects of TemperatureChecking Battery State of Charge Charging a BatteryStarter Contactor & Motor Preheat SwitchSTART/STOP Switch AMP FuseGlow Plugs Engine GovernorFuel Injection Pump Fuel NOZZLES/INJECTORSOverspeed Protection LOW OIL Pressure Switch High Coolant Temperature SwitchAdapter LOW OIL Pressure Switch Engine Protective DevicesTroubleshooting Flowcharts Troubleshooting Flowcharts Problem 3 No Battery Charge Output Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Test 1- Check NO-LOAD Voltage Frequency Test 2 Check & AdjustTest 4- Fixed Excitation TEST/ROTOR AMP Draw Test 3- Test Excitation Circuit BreakerSet a VOM to its Rx1 scale Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Test 6- Check Field BoostModel QP75D Test 7 Test Stator DPE Winding184W Test 8- Check Sensing Leads / Power WindingsTest 9- Check Brush Leads 159WTance Tests Procedure Test 11- Check Rotor AssemblyTest 10 Check Brushes & Slip Rings Test 14- Check Load Watts & Amperage Test 15 Check Battery Charge OutputTest 12 Check Main Circuit Breaker Test 13- Check Load Voltage FrequencyBattery Charge Rectifier BCR is a full wave rectifier Test 16 Check Battery Charge RectifierShort to Ground Test 20- Check Fuel Pump Test 19- Test PRE-HEAT SwitchSet a VOM to read battery voltage 12 VDC Test 18 TRY Cranking the EngineTest 21- Check 14 AMP Fuse Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board Disconnect the connector from the wires of the fuel pumpNot Activated Test 24 Check START-STOP SwitchTest 27 Check Starter Motor Test 26- Test Starter ContactorConditions Affecting Starter Motor Performance Measuring Current Checking the PinionPinion Tools for Starter Performance TestStarter motor test bracket may be made as shown in Figure Testing Starter MotorTachometer Test BracketTest 28- Check Fuel Supply Test 29 Check Wire 14 Power SupplyTest 30 Check Wire If Wire 18 checks GOOD, proceed to Problem 8 SectionTest 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 Repeat Steps 1 through 8 on remaining cylinder If fuel is noted, proceed to next step in flowchartAdjust the regulated pressure on the gauge to 80 psi Down Test / Compression TestTest 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 Belt Tensioning RE-ASSEMBLYFAN Belt Line Corner UP Between 5˚ to 10˚Section Exploded Views / Part Numbers Bearing Carrier, Front Rotor AssemblyStator Assembly Flywheel AssemblyBase Frame Drawing No D2357-A Slide Latch Flush Door, Service RearDoor, Service Front Base Frame WeldmentEnclosure Drawing No D2358-D Decal, Battery + Cover, Access LiftCover, Access Electrical Gasket, Electrical AccessViews / Part Cover Plate, Scroll Weldment 25 26 Wire Assembly # Assembly, Potted RegulatorAssembly Marine Control Board Rectifier, Battery ChargingIntake and Exhaust System Drawing No D2362-B Hose, Air Inlet Exhaust GasketChamber Air Intake Air FilterViews / Part Numbers Wire Assembly, Black #4 Ground Fuel Pump AssemblyBoot, Battery Cable Cable, BatteryCustomer Controls Assembly Drawing No D2364-D Boot, Circuit Breaker Start / Stop SwitchSwitch, Pushbutton Spst Boot / Nut / Preheat SwitchGear Camshaft AssemblyCamshaft Gear KEY2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B OIL Pump Cover Idler Gear AssemblySpring Thrust WasherExhaust Rocker ARM Rocker ARM AssemblyIncludes ALL Components Shown below Intake Rocker ARMLiter 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 Generator Specifications Engine SpecificationsType Quietpact Model ROTOR/STATOR Resistance ValuesPage Data Data Electrical Data C4945 Schematic Drawing No C4945-A ModelC4946-A ElectricalSheet 2 OF4996 REV. O