Troubleshooting Flowcharts | Guardian Technologies 4270 instruction

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

Guardian Technologies 4270 manual Troubleshooting Flowcharts

Contents

Diagnostic Repair Manual Replacement Parts Safety Table of Contents 57-59 Electromagnetic Fields MagnetismElectromagnetic Induction More Sophisticated AC Generator Simple AC Generator Generator 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 Assembly General Battery Charge ComponentsBrush Holder Excitation Circuit Components Voltage Regulator Adjust POT LEDAdjustment Procedure 162 Control Panel Components Control Panel Component Identification Insulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the Generator Stator SHORT-TO-GROUND Tests Brushing and Vacuum CleaningStator Insulation Resistance Cloth or Compressed AIR Megohmmeter Testing Rotor Insulation Measuring DC Voltage MetersVOM Measuring AC Voltage Measuring Current Measuring AC FrequencyMeasuring Resistance Ohms LAW Electrical Units Operational 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 Battery Adding Water Effects of TemperatureChecking Battery State of Charge Charging a Battery Starter Contactor & Motor Preheat SwitchSTART/STOP Switch AMP Fuse Glow Plugs Engine GovernorFuel Injection Pump Fuel NOZZLES/INJECTORS Overspeed Protection LOW OIL Pressure Switch High Coolant Temperature SwitchAdapter LOW OIL Pressure Switch Engine Protective Devices Troubleshooting 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 & Adjust Test 4- Fixed Excitation TEST/ROTOR AMP Draw Test 3- Test Excitation Circuit Breaker Set a VOM to its Rx1 scale Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Test 6- Check Field Boost Model QP75D Test 7 Test Stator DPE Winding 184W Test 8- Check Sensing Leads / Power WindingsTest 9- Check Brush Leads 159W Tance 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 Frequency Battery 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 Engine Test 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 pump Not Activated Test 24 Check START-STOP Switch Test 27 Check Starter Motor Test 26- Test Starter ContactorConditions Affecting Starter Motor Performance Measuring Current Checking the PinionPinion Tools for Starter Performance Test Starter motor test bracket may be made as shown in Figure Testing Starter MotorTachometer Test Bracket Test 28- Check Fuel Supply Test 29 Check Wire 14 Power SupplyTest 30 Check Wire If Wire 18 checks GOOD, proceed to Problem 8 Section Test 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 Test Test 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-ASSEMBLY FAN Belt Line Corner UP Between 5˚ to 10˚ Section Exploded Views / Part Numbers Bearing Carrier, Front Rotor AssemblyStator Assembly Flywheel Assembly Base Frame Drawing No D2357-A Slide Latch Flush Door, Service RearDoor, Service Front Base Frame Weldment Enclosure Drawing No D2358-D Decal, Battery + Cover, Access LiftCover, Access Electrical Gasket, Electrical Access Views / Part Cover Plate, Scroll Weldment 25 26 Wire Assembly # Assembly, Potted RegulatorAssembly Marine Control Board Rectifier, Battery Charging Intake and Exhaust System Drawing No D2362-B Hose, Air Inlet Exhaust GasketChamber Air Intake Air Filter Views / Part Numbers Wire Assembly, Black #4 Ground Fuel Pump AssemblyBoot, Battery Cable Cable, Battery Customer Controls Assembly Drawing No D2364-D Boot, Circuit Breaker Start / Stop SwitchSwitch, Pushbutton Spst Boot / Nut / Preheat Switch Gear Camshaft AssemblyCamshaft Gear KEY 2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B OIL Pump Cover Idler Gear AssemblySpring Thrust Washer Exhaust Rocker ARM Rocker ARM AssemblyIncludes ALL Components Shown below Intake Rocker ARM Liter 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 Specifications Type Quietpact Model ROTOR/STATOR Resistance ValuesPage Data Data Electrical Data C4945 Schematic Drawing No C4945-A Model C4946-A Electrical Sheet 2 OF4996 REV. O