Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4270 manual Section TROUBLESHOOTING FLOWCHARTS, Introduction, Page

Models: 4270

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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.

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Guardian Technologies 4270 manual Section TROUBLESHOOTING FLOWCHARTS, Introduction, Page

Contents

MODEL DIAGNOSTIC REPAIR MANUALRECREATIONAL VEHICLE GENERATOR QUIETPACT 75DREPLACEMENT PARTS SAFETYNOTICE TO USERS OF THIS MANUAL TROUBLESHOOTING FLOWCHARTS Table of ContentsGENERATOR FUNDAMENTALS Check Battery Charge Windings Table of ContentsCheck Rotor Assembly Check Battery Charge OutputELECTROMAGNETIC INDUCTION Section GENERATOR FUNDAMENTALSMAGNETISM ELECTROMAGNETIC FIELDSFigure 1-4. - A Simple AC Generator A SIMPLE AC GENERATORA MORE SOPHISTICATED AC GENERATOR Figure 1-5. - Alternating Current Sine WaveSection GENERATOR FUNDAMENTALS Figure 1-7. - Generator Operating DiagramGenerator operation may be described briefly as fol- lows Section GENERATOR FUNDAMENTALS FIELD BOOSTGENERATOR AC CONNECTION SYSTEM GENERATOR CONVERSION TO 120 VAC ONLY - DUAL CIRCUITSSection GENERATOR FUNDAMENTALS Figure 1-8. - Connection for 120/240 VAC Dual VoltageFigure 1-9 - Connection for 120 VAC Only - Dual Circuits 7. Remove the tie bar between the two-line breaker switch han- dlesFigure 2-1. Exploded View of Generator ROTOR ASSEMBLYSTATOR ASSEMBLY Section MAJOR GENERATOR COMPONENTSBRUSH HOLDER BATTERY CHARGE COMPONENTSFigure 2-4. - Battery Charge Circuit Figure 2-5. - Schematic Excitation CircuitVOLTAGE REGULATOR Figure 2-6. - Excitation Circuit BreakerFigure 2-7. - Voltage Regulator Section MAJOR GENERATOR COMPONENTSPage CONTROL PANEL COMPONENT IDENTIFICATIONFigure 2-9. - Control Panel Components Section MAJOR GENERATOR COMPONENTSDRYING THE GENERATOR CLEANING THE GENERATORSection INSULATION RESISTANCE TESTS EFFECTS OF DIRT AND MOISTUREFigure 3-2. - Stator Leads STATOR INSULATION RESISTANCESection INSULATION RESISTANCE TESTS Section INSULATION RESISTANCE TESTS TESTING ROTOR INSULATIONTHE MEGOHMMETER Figure 3-3. - Rotor Test PointsMEASURING AC VOLTAGE Section MEASURING ELECTRICITYMETERS THE VOMFigure 4-2. - Clamp-On Ammeter MEASURING AC FREQUENCYMEASURING CURRENT MEASURING RESISTANCEAMPERES = VOLTSOHMS ELECTRICAL UNITSOHMS LAW Figure 4-4. - Electrical UnitsINTRODUCTION Section ENGINE DC CONTROL SYSTEMOPERATIONAL ANALYSIS CIRCUIT CONDITION- PRE-HEAT Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION- CRANKING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION-RUNNING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION- SHUTDOWN Section ENGINE DC CONTROL SYSTEMSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- FAULT SHUTDOWNSSection ENGINE DC CONTROL SYSTEM BATTERYENGINE CONTROL CIRCUIT BOARD WIRENOTE Water cannot be added to some “mainte- nance-free” batteries SectionENGINE DC CONTROL SYSTEM Figure 5-4 - Engine Control Circuit BoardB. Schematic PREHEAT SWITCHSTART/STOP SWITCH A. SchematicGLOW PLUGS ENGINE GOVERNORFUEL INJECTION PUMP FUEL NOZZLES/INJECTORSENGINE PROTECTIVE DEVICES LOW OIL PRESSURE SWITCHHIGH COOLANT TEMPERATURE SWITCH Figure 5-13. - High Coolant Temperature SwitchPage Section TROUBLESHOOTING FLOWCHARTSProblems 1 through 4 apply to the AC generator only INTRODUCTIONPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSProblem 3 - No Battery Charge Output continuedPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSTEST 1- CHECK NO-LOAD VOLTAGE AND FREQUENCY DIAGNOSTIC TESTSTEST 2 - CHECK & ADJUST Figure 7-1. - Governor Adjustment PointsFigure 7-2. - Excitation “DPE” Circuit Breaker Section DIAGNOSTIC TESTSTEST 3- TEST EXCITATION CIRCUIT BREAKER TEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAWTEST 4 RESULTS TEST 5- WIRE CONTINUITYTEST 6- CHECK FIELD BOOST Section DIAGNOSTIC TESTSFigure 7-4. - Stator Excitation Winding TEST 7 - TEST STATOR DPE WINDINGSection DIAGNOSTIC TESTS Section DIAGNOSTIC TESTS TEST 8- CHECK SENSING LEADS / POWER WINDINGSFigure 7-5. - Stator Power Winding Leads TEST 9- CHECK BRUSH LEADSFigure 7-6. - Brush Leads TEST 11- CHECK ROTOR ASSEMBLYFigure 7-7. - Rotor Assembly TEST 10 - CHECK BRUSHES & SLIP RINGSTEST 14- CHECK LOAD WATTS & AMPERAGE TEST 15 - CHECK BATTERY CHARGE OUTPUTTEST 12 - CHECK MAIN CIRCUIT BREAKER TEST 13- CHECK LOAD VOLTAGE FREQUENCYSection DIAGNOSTIC TESTS TEST 16 - CHECK BATTERY CHARGE RECTIFIERTEST 17 - CHECK BATTERY CHARGE WINDINGS / BATTERY CHARGE RESISTOR Figure 7-9. - Battery Charge RectifierTEST 20- CHECK FUEL PUMP TEST 19- TEST PRE-HEAT SWITCHPre-Heat Switch TEST 18 - TRY CRANKING THE ENGINEFigure 7-11. - 14 Amp Fuse TEST 22- CHECK BATTERY & CABLESTEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD TEST 21- CHECK 14 AMP FUSESection DIAGNOSTIC TESTS TEST 24 - CHECK START-STOP SWITCHFigure 7-12. - Start-Stop Switch Figure 7-13. - Test 24, StepSection DIAGNOSTIC TESTS TEST 25 - CHECK POWER SUPPLY TO WIRETEST 26- TEST STARTER CONTACTOR TEST 27 - CHECK STARTER MOTORFigure 7-15. - Check Starter Pinion Figure 7-14. - Starter Motor SMSection DIAGNOSTIC TESTS Figure 7-18. - Test Bracket Figure 7-19. - Testing Starter Motor PerformanceFigure 7-16. - Clamp-On Ammeter Figure 7-17. - TachometerTEST 28- CHECK FUEL SUPPLY TEST 29 - CHECK WIRE 14 POWER SUPPLYTEST 30 - CHECK WIRE Figure 7-20. - Remote Harness ConnectorSection DIAGNOSTIC TESTS TEST 32- TEST PREHEAT CONTACTORTEST 33- TEST GLOW PLUGS TEST 34- TEST D1 DIODETEST 36- FUEL INJECTOR PUMP TEST 35- CHECK VALVE ADJUSTMENTFigure 7-22. - Valve Adjustment Points Figure 7-23. - Checking Valve AdjustmentTEST 37 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TESTSection DIAGNOSTIC TESTS TEST 39- CHECK CIRCUIT BOARD FOR GROUND TEST 38 - CHECK OIL PRESSURE SWITCHTEST 40- TEST WATER TEMPERATURE SWITCH Figure 7-23. - Oil Pressure SwitchCOMPONENTS FOR SHORT TO GROUND TEST 43 - CHECK WIRE 15 FOR SHORT TO GROUNDTEST 41- CHECK WIRE 14 AND CONNECTING TEST 42 - CHECK WIRE 56 AND STARTER CONTACTOR FOR SHORT TO GROUNDFigure 8-1. - Block of Wood Under Rear of Engine Section ASSEMBLYMAJOR DISASSEMBLY Figure 8-2. - Using Prybar to Stabilize FlywheelFigure 8-4. - Drive Belt Tensioner RE-ASSEMBLYBELT TENSIONING Figure 8-3. - Radiator Removal PointsFigure 8-8. - Leveling Fan Belt Tensioner Figure 8-5. - Applying Tension to Drive Belt TensionerFigure 8-6. - Position of Drive Belt Tensioner Figure 8-7. - Position of Fan Belt TensionerPage Section Exploded Views / Part Numbers43 7 Engine, Alternator Drive & Starter - Drawing No. 0D2355-BDESCRIPTION Section Exploded Views / Part NumbersBase Frame - Drawing No. 0D2357-A Section Exploded Views / Part NumbersPage DESCRIPTION Section Exploded Views / Part NumbersEnclosure - Drawing No. 0D2358-D Section Exploded Views / Part NumbersPage Enclosure Panel RH Section Exploded Views / Part Numbers3034 Views / PartNumbers ExplodedSection Exploded Views / Part NumbersHousing, Fan Scroll Weldment Filler Neck Assembly, Radiator Remote28 1 27 29 Electrical Enclosure Assembly - Drawing No. 0D2361-ESection Exploded Views / Part Numbers PageExploded Views / Part Numbers SectionDESCRIPTION TO ENGINE AIR INTAKE Section Exploded Views / Part NumbersIntake and Exhaust System - Drawing No. 0D2362-B PageDESCRIPTION Section Exploded Views / Part NumbersExploded Views / Part Numbers1 2 12 2 SectionExploded Views / Part Numbers SectionDESCRIPTION Section Exploded Views / Part Numbers Customer Controls Assembly - Drawing No. 0D2364-DPage Exploded Views / Part Numbers SectionDESCRIPTION 1.0 Liter Diesel Camshaft - Drawing No Section Exploded Views / Part Numbers1.0 Liter Diesel Cylinder Block - Drawing No 2630CONNECTOR Section Exploded Views / Part NumbersSection Exploded Views / Part Numbers CYLINDER HEAD ASSEMBLYOIL SWITCH THERMO-SWITCHBEARING HOLDER ASSEMBLY CRANKSHAFT ASSEMBLYBEARING HOLDER ASSEMBLY CONNECTING ROD ASSEMBLY1.0 Liter Diesel Oil Pump - Drawing No Section Exploded Views / Part NumbersSection Exploded Views / Part Numbers 1.0 Liter Diesel Rocker Arm Assembly - Drawing No1.0 Liter Diesel Injector Pump - Drawing No. 075686-C INJECTOR PUMP ASSEMBLYCONNECTOR Section Exploded Views / Part NumbersTo Fuel Pump Tank ReturnModel 04270 To Injection Pump1.0 Liter Diesel Timing and Governor - Drawing No. 082067-B 27 2519 18 Section Exploded Views / Part NumbersExploded Views / Part Numbers HOUSING, TIMING GEARGOVERNOR LEVER ASSEMBLY SectionDESCRIPTION 3114Section Exploded Views / Part Numbers 1.0 Liter Diesel Engine Block - Drawing No. 082961-CPLUG WATER PUMP ASSEMBLYSection Exploded Views / Part Numbers 1.0 Liter Diesel Water Pump - Drawing NoSection CHARTSSPECIFICATIONS Major Features and Dimensions - Drawing No. 0D2650-ADisplacement SPECIFICATIONS & CHARTSENGINE SPECIFICATIONS GENERATOR SPECIFICATIONSTORQUE SPECIFICATIONS Section SPECIFICATIONS & CHARTSROTOR/STATOR RESISTANCE VALUES Page Page DATAELECTRICAL SectionELECTRICAL Section 11 DATAWIRE DIAGRAM, 1.0L DSL 120VAC 35A OutputPage Section ELECTRICAL DATASchematic - Drawing No. 0D2792-A Models 04270-1 SCHEMATIC 1.0L DIESELPage Schematic - Drawing No. 0C4945-A ModelSection ELECTRICAL DATA C4945Page Section 11 ELECTRICALWiring Diagram WIRE DIAGRAM, 1.0L DSLSection 11 DATA WIRE DIAGRAM, 1.0L DSLSHEET 2 OF DUAL 120VAC, 35A OUTPUTPRINTED IN THE USA/1.05 P/N OF4996 REV. 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