I have a similar but different starting problem from the other 804A start problem threads. I've read everything in those threads and I think I've done all of those tests (details below) so I "guess" I'm down to the governor module being the problem but I want to be sure first before just throwing parts at it.
Background: I've had my set about 5 years but only used it a handful of times during storm outages. I ran test cycles every few months but not super religiously. The only thing I noticed was that it was originally very quick to start--only a couple of seconds to catch and then come up to speed-- and then progressively slower to start requiring me to hold the start switch for longer and longer each time. The last time it started and ran correctly I had to hold it in start for maybe 20 seconds.
Current state: Batteries have been recharged and it will turn over at full speed but does not fire at all. Sometimes there is a small amount of unburnt fuel smoke when attempting to start but it's not very much, nothing like it did when it started.
I do have the TMs and have read them backwards and forward until I'm now blind to what must surely be obvious. Details below but I I think I've narrowed it down to either the governor module not outputting the correct control signal or the governor actuator not reacting to it.
Troubleshooting steps I've taken so far:
* Fuel tank - the last time it ran I nearly emptied the tank but did not run out. I've since filled it full ( which results in the priming pump not running in the "prime' position which was my first "goose chase." I've confirmed the fuel pump runs and when cranking over there is fuel to the injection pump
* Injection pump & prime - I've checked that fuel is flowing to each injector and bleed the system
* governor actuator - I've checked that the throttle solenoid has the right impedance, it works and responds correctly to voltage/current
* MPU - checked & reseated. It is outputting the correct voltage (I've even verified hte signal on an oscilloscope)
* wiring - I did find a mouse nest but could not find any damaged wires. I've checked continuity on all of the circuited relating to start
* start switch (S1) - I've tested that all the circuits make according to the schematic on page 817 (ARMY TM 9-6115-643-24)
* governor module (Woodward 8270-1002) - I've checked the DC voltage in and MPU signal into the module and continuity to the governor actuator. HOWEVER, I have NOT been able to confirm what the module should be outputting to the governor actuator so that's unknown
Known Good:
The engine did fire up immediately when I manually set the throttle position so I know the engine, fuel, and fuel pumps are good, it's most likely a problem in (or before) the governor actuator.
New mistakes:
1. When I tested the S1 I carefully labeled the wires and thought I put them back correctly but now the hour meter runs anytime the dead crank switch is in Normal so I obviously got something wrong. I have not been able to find the page in the TM that lists the correct wire numbers and positions. I need to fix this before I move on troubleshooting.
Special notes:
1. The Woodward Governor module already had all the wires numbered when I started so somebody has been in here before. But it worked when I got it so I don't immediately suspect that.
2. The fuse mod is present.
3. I've seen mentions about another mod (MOV? I don't remember) but I don't know what that is or if I need it.
4. Once I have it working again I want to do the single-phase conversion and add kloppk's remote start kit. This will be the standby generator for my off-grid solar setup
5. Set has 803 hours on it so far, about 30 of those are mine.
Ask:
1. Can anybody point me at the right wire numbers for the S1 switch?
2. What do I troubleshoot next?
3. Is it time to try replacing the governor module? If so, what caused it to fail? Since this is obviously at least the 2nd module in it is it possible that something else is wrong that's burning up the governor modules?
Images of placards, front cover, and engine bay attached.
Thanks in advance!
Background: I've had my set about 5 years but only used it a handful of times during storm outages. I ran test cycles every few months but not super religiously. The only thing I noticed was that it was originally very quick to start--only a couple of seconds to catch and then come up to speed-- and then progressively slower to start requiring me to hold the start switch for longer and longer each time. The last time it started and ran correctly I had to hold it in start for maybe 20 seconds.
Current state: Batteries have been recharged and it will turn over at full speed but does not fire at all. Sometimes there is a small amount of unburnt fuel smoke when attempting to start but it's not very much, nothing like it did when it started.
I do have the TMs and have read them backwards and forward until I'm now blind to what must surely be obvious. Details below but I I think I've narrowed it down to either the governor module not outputting the correct control signal or the governor actuator not reacting to it.
Troubleshooting steps I've taken so far:
* Fuel tank - the last time it ran I nearly emptied the tank but did not run out. I've since filled it full ( which results in the priming pump not running in the "prime' position which was my first "goose chase." I've confirmed the fuel pump runs and when cranking over there is fuel to the injection pump
* Injection pump & prime - I've checked that fuel is flowing to each injector and bleed the system
* governor actuator - I've checked that the throttle solenoid has the right impedance, it works and responds correctly to voltage/current
* MPU - checked & reseated. It is outputting the correct voltage (I've even verified hte signal on an oscilloscope)
* wiring - I did find a mouse nest but could not find any damaged wires. I've checked continuity on all of the circuited relating to start
* start switch (S1) - I've tested that all the circuits make according to the schematic on page 817 (ARMY TM 9-6115-643-24)
* governor module (Woodward 8270-1002) - I've checked the DC voltage in and MPU signal into the module and continuity to the governor actuator. HOWEVER, I have NOT been able to confirm what the module should be outputting to the governor actuator so that's unknown
Known Good:
The engine did fire up immediately when I manually set the throttle position so I know the engine, fuel, and fuel pumps are good, it's most likely a problem in (or before) the governor actuator.
New mistakes:
1. When I tested the S1 I carefully labeled the wires and thought I put them back correctly but now the hour meter runs anytime the dead crank switch is in Normal so I obviously got something wrong. I have not been able to find the page in the TM that lists the correct wire numbers and positions. I need to fix this before I move on troubleshooting.
Special notes:
1. The Woodward Governor module already had all the wires numbered when I started so somebody has been in here before. But it worked when I got it so I don't immediately suspect that.
2. The fuse mod is present.
3. I've seen mentions about another mod (MOV? I don't remember) but I don't know what that is or if I need it.
4. Once I have it working again I want to do the single-phase conversion and add kloppk's remote start kit. This will be the standby generator for my off-grid solar setup
5. Set has 803 hours on it so far, about 30 of those are mine.
Ask:
1. Can anybody point me at the right wire numbers for the S1 switch?
2. What do I troubleshoot next?
3. Is it time to try replacing the governor module? If so, what caused it to fail? Since this is obviously at least the 2nd module in it is it possible that something else is wrong that's burning up the governor modules?
Images of placards, front cover, and engine bay attached.
Thanks in advance!
