Troubleshooting Flowcharts | Guardian Technologies 4270 guide

Section 6

TROUBLESHOOTING FLOWCHARTS

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Guardian Technologies 4270 manual Troubleshooting Flowcharts

Contents

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