Guardian Technologies 4270 manual Test 16 Check Battery Charge Rectifier, Short to Ground

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Section 7

DIAGNOSTIC TESTS

approximately 0.8 Amps. Apply full load to the generator. The amp 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 functioning of the Amp Meter. If DC Amp Meter is good and no current is measured, go to Test 16

TEST 16 - CHECK BATTERY CHARGE

RECTIFIER

DISCUSSION:

The Battery Charge Rectifier (BCR) is a full wave rectifier.

PROCEDURE:

1.Disconnect Wire 66, Wire 15 and Wire 77 from the Battery Charge Rectifier.

2.Set the VOM to the Diode Test range. Connect the negative (-) test lead to the center terminal of the BCR. Connect the posi- tive (+) test lead to an outer terminal. The meter should mea- sure approximately 0.47 to 0.5 volts.

3.Connect the positive (+) test lead to the center terminal of the BCR. Connect the negative (-) test lead to to an outer terminal. The meter should measure “Infinity.” Connect the negative test lead to the other outer terminal. “Infinity” should once again be measured.

Short to Ground:

4.Set the VOM to measure resistance. Connect the positive (+) test lead to the case housing of the BCR. Connect the negative (-) test lead to an outer terminal. “Infinity” should be measured. Now connect the negative test lead to the BCR center terminal. “Infinity” should be measured. Next, connect the negative test lead to the remaining outer BCR terminal. Once again “Infinity” should be measured.

66

15

77

Figure 7-9. – Battery Charge Rectifier

RESULTS:

1.If any of the previous steps has failed, replace the Battery Charge Rectifier.

TEST 17 - CHECK BATTERY CHARGE

WINDINGS / BATTERY CHARGE RESISTOR

DISCUSSION:

The Battery Charge Winding (BCW) produces AC voltage that is delivered to the Battery Charge Rectifier. The Battery Charge Winding is a center tapped winding consisting of the following Stator Leads: Wire 66, Wire 77 and Wire 55. The Battery Charge Resistor is used as a current limiting resistor.

PROCEDURE:

1.Disconnect the Stator Leads (Wire 66 and Wire 77) from the Battery Charge Rectifier. (Be sure to disconnect Stator Lead Wire 66 “Black” from Wire 66 “Blue” connector for this test). Disconnect the Stator Lead Wire 55 from the Battery Charge Resistor.

2.Set the VOM to measure resistance at the “R x 1” scale. Connect one test lead to Stator Lead Wire 66. Connect the other test lead to Stator Lead Wire 55. Normal Battery Charge Winding resistance should be measured.

3.Connect one test lead to Stator Lead Wire 77. Connect the other test lead to Stator Lead Wire 55. Normal Battery Charge Winding resistance should be measured.

4.Connect one test lead to Stator Lead Wire 55. Connect the other test lead to Stator Leads Wire 11 & 33 at the back of CB1. “Infinity” should be measured.

5.Connect one test lead to Stator Lead Wire 55. Disconnect Stator Lead Wire 2 from the DPE circuit breaker (CB2) and connect the other test lead to Wire 2. “Infinity” should be mea- sured.

6Connect one test lead to Stator Lead Wire 55. Connect the other test lead to frame ground. “Infinity” should be measured.

7.Connect one test lead to the Battery Charge Resistor terminal that Wire 55 was removed from. Connect the other test lead to frame ground. One (1) ohm should be measured. If 1 ohm was not measured, remove Wire 0 from the Battery Charge Resistor. Connect one test lead to Wire 0 and the other test lead to frame ground. “Continuity” should be measured. Repair or replace Wire 0 if defective and retest the Battery Charge Resistor.

BATTERY CHARGE WINDING RESISTANCE *

QP75D (Model 4270)

ACROSS WIRES:

OHMS

55 & 66

0.7Ω

55 & 77

0.5Ω

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents 57-59 Electromagnetic Fields MagnetismElectromagnetic Induction Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostLine Breakers 120 VAC only 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 Current Measuring AC FrequencyMeasuring Resistance Electrical Units Ohms LAWOperational Analysis IntroductionCircuit CONDITION- OFF 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 184WTance Tests Procedure Test 11- Check Rotor AssemblyTest 10 Check Brushes & Slip Rings Test 13- Check Load Voltage Frequency Test 15 Check Battery Charge OutputTest 12 Check Main Circuit Breaker Test 14- Check Load Watts & AmperageBattery Charge Rectifier BCR is a full wave rectifier Test 16 Check Battery Charge RectifierShort to Ground 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 ActivatedTest 27 Check Starter Motor Test 26- Test Starter ContactorConditions Affecting Starter Motor Performance 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 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 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 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 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. O
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