Guardian Technologies 4270 manual Troubleshooting Flowcharts

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Section 6

TROUBLESHOOTING FLOWCHARTS

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents 57-59 Electromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Line Breakers 120 VAC only Field BoostGenerator AC Connection System Connection for 120/240 VAC Dual Voltage Rotor Assembly LIC Grit or Abrasive to Clean Slip RingsExcitation Circuit Components Battery Charge ComponentsBrush Holder General162 Adjust POT LEDAdjustment Procedure Voltage RegulatorControl Panel Component Identification Control Panel ComponentsDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersCloth or Compressed AIR Brushing and Vacuum CleaningStator Insulation Resistance Stator SHORT-TO-GROUND TestsTesting Rotor Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Resistance Measuring AC FrequencyMeasuring Current Electrical Units Ohms LAWCircuit CONDITION- OFF IntroductionOperational Analysis Circuit CONDITION- PRE-HEAT Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Circuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdowns Battery Engine Control Circuit BoardCharging a Battery Effects of TemperatureChecking Battery State of Charge Adding WaterAMP Fuse Preheat SwitchSTART/STOP Switch Starter Contactor & MotorFuel NOZZLES/INJECTORS Engine GovernorFuel Injection Pump Glow PlugsEngine Protective Devices LOW OIL Pressure Switch High Coolant Temperature SwitchAdapter LOW OIL Pressure Switch Overspeed ProtectionTroubleshooting Flowcharts Troubleshooting Flowcharts Problem 3 No Battery Charge Output Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Test 2 Check & Adjust Test 1- Check NO-LOAD Voltage FrequencyTest 3- Test Excitation Circuit Breaker Test 4- Fixed Excitation TEST/ROTOR AMP DrawTest 6- Check Field Boost Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Set a VOM to its Rx1 scaleTest 7 Test Stator DPE Winding Model QP75D159W Test 8- Check Sensing Leads / Power WindingsTest 9- Check Brush Leads 184WTest 10 Check Brushes & Slip Rings Test 11- Check Rotor AssemblyTance Tests Procedure Test 13- Check Load Voltage Frequency Test 15 Check Battery Charge OutputTest 12 Check Main Circuit Breaker Test 14- Check Load Watts & AmperageShort to Ground Test 16 Check Battery Charge RectifierBattery Charge Rectifier BCR is a full wave rectifier Test 18 TRY Cranking the Engine Test 19- Test PRE-HEAT SwitchSet a VOM to read battery voltage 12 VDC Test 20- Check Fuel PumpDisconnect the connector from the wires of the fuel pump Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board Test 21- Check 14 AMP FuseTest 24 Check START-STOP Switch Not ActivatedConditions Affecting Starter Motor Performance Test 26- Test Starter ContactorTest 27 Check Starter Motor Tools for Starter Performance Test Checking the PinionPinion Measuring CurrentTest Bracket Testing Starter MotorTachometer Starter motor test bracket may be made as shown in FigureIf Wire 18 checks GOOD, proceed to Problem 8 Section Test 29 Check Wire 14 Power SupplyTest 30 Check Wire Test 28- Check Fuel SupplyTest 34- Test D1 Diode Test 32- Test Preheat ContactorTest 33- Test Glow Plugs Test 36- Fuel Injector Pump Test 35- Check Valve AdjustmentRemove the valve cover from engine Disconnect the battery Down Test / Compression Test If fuel is noted, proceed to next step in flowchartAdjust the regulated pressure on the gauge to 80 psi Repeat Steps 1 through 8 on remaining cylinderTest 39- Check Circuit Board for Ground Test 38 Check OIL Pressure SwitchTest 40- Test Water Temperature Switch Components for Short to Ground Test 43 Check Wire 15 for Short to GroundIf continuity is measure, replace the switch Major Disassembly RE-ASSEMBLY Belt TensioningLine Corner UP Between 5˚ to 10˚ FAN BeltSection Exploded Views / Part Numbers Flywheel Assembly Rotor AssemblyStator Assembly Bearing Carrier, FrontBase Frame Drawing No D2357-A Base Frame Weldment Door, Service RearDoor, Service Front Slide Latch FlushEnclosure Drawing No D2358-D Gasket, Electrical Access Cover, Access LiftCover, Access Electrical Decal, Battery +Views / Part Cover Plate, Scroll Weldment 25 26 Rectifier, Battery Charging Assembly, Potted RegulatorAssembly Marine Control Board Wire Assembly #Intake and Exhaust System Drawing No D2362-B Air Filter Exhaust GasketChamber Air Intake Hose, Air InletViews / Part Numbers Cable, Battery Fuel Pump AssemblyBoot, Battery Cable Wire Assembly, Black #4 GroundCustomer Controls Assembly Drawing No D2364-D Boot / Nut / Preheat Switch Start / Stop SwitchSwitch, Pushbutton Spst Boot, Circuit BreakerKEY Camshaft AssemblyCamshaft Gear Gear2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B Thrust Washer Idler Gear AssemblySpring OIL Pump CoverIntake Rocker ARM Rocker ARM AssemblyIncludes ALL Components Shown below Exhaust 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 Engine Specifications Generator SpecificationsROTOR/STATOR Resistance Values Type Quietpact ModelPage Data Data Electrical Data Schematic Drawing No C4945-A Model C4945Electrical C4946-ASheet 2 OF4996 REV. 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