Guardian Technologies 4270 manual Circuit CONDITION- Fault Shutdowns

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Section 5

ENGINE DC CONTROL SYSTEM

CIRCUIT CONDITION- FAULT SHUTDOWNS:

The engine has mounted to it a HIGH WATER TEM- PERATURE SWITCH (HWT) and a LOW OIL PRES- SURE SWITCH (LOS). While running, ENGINE CONTROL circuit board action keeps Terminal 12 Wire 85 energized with battery voltage. Connected in parallel to (Wire 85) are the LOW OIL PRESSURE SWITCH (LOS) and HIGH WATER TEMP SWITCH (HWT). The (LOS) has normally closed contacts. After start-up, engine oil pressure will open the con- tacts. The HWT has normally open contacts. High coolant temperature will close the contacts.

Should engine water temperature exceed a preset value, the switch contacts will close. Wire 85 from the circuit board will connect to ground. Circuit board action will then initiate a shutdown.

Should engine oil pressure drop below a safe pre-set value, the switch contacts will close.

On contact closure, Wire 85 will be connected to ground and circuit board action will initiate an engine shutdown.

The circuit board has a time delay built into it for the Wire 85 fault shutdowns. At STARTUP ONLY the cir- cuit board will wait approximately six (6) seconds before looking at the Wire 85 fault shutdowns. Once running after the six (6) second time delay, grounding Wire 85 through either switch will cause an immedi- ate shutdown.

The ENGINE CONTROL circuit board also has over- speed protection. The circuit board senses the AC output from the stators POWER winding at Terminals 5 & 6 via Wires 22 & 44. This AC voltage and fre- quency signal is used indirectly to monitor engine RPM. If the frequency should increase above a pre- set "adjustable" limit, the ENGINE CONTROL circuit board will cause an immediate shutdown.

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents 57-59 Electromagnetic Fields MagnetismElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator 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 AssemblyBrush Holder Battery Charge ComponentsExcitation Circuit Components GeneralAdjustment Procedure Adjust POT LED162 Voltage RegulatorControl Panel Components Control Panel Component IdentificationEffects of Dirt and Moisture Cleaning the GeneratorDrying the Generator Insulation Resistance TestersStator Insulation Resistance Brushing and Vacuum CleaningCloth or Compressed AIR Stator SHORT-TO-GROUND TestsMegohmmeter Testing Rotor InsulationVOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring AC FrequencyMeasuring Resistance Ohms LAW Electrical UnitsOperational 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 BatteryChecking Battery State of Charge Effects of TemperatureCharging a Battery Adding WaterSTART/STOP Switch Preheat SwitchAMP Fuse Starter Contactor & MotorFuel Injection Pump Engine GovernorFuel NOZZLES/INJECTORS Glow PlugsAdapter LOW OIL Pressure Switch LOW OIL Pressure Switch High Coolant Temperature SwitchEngine Protective Devices Overspeed ProtectionTroubleshooting 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 & AdjustTest 4- Fixed Excitation TEST/ROTOR AMP Draw Test 3- Test Excitation Circuit BreakerRe-connect Wire 11 and Wire 22 to the Voltage Regulator Test 5- Wire ContinuityTest 6- Check Field Boost Set a VOM to its Rx1 scaleModel QP75D Test 7 Test Stator DPE WindingTest 9- Check Brush Leads Test 8- Check Sensing Leads / Power Windings159W 184WTance Tests Procedure Test 11- Check Rotor AssemblyTest 10 Check Brushes & Slip Rings Test 12 Check Main Circuit Breaker Test 15 Check Battery Charge OutputTest 13- Check Load Voltage Frequency Test 14- Check Load Watts & AmperageBattery Charge Rectifier BCR is a full wave rectifier Test 16 Check Battery Charge RectifierShort to Ground Set a VOM to read battery voltage 12 VDC Test 19- Test PRE-HEAT SwitchTest 18 TRY Cranking the Engine Test 20- Check Fuel PumpTest 23- Check Power Supply to Circuit Board Test 22- Check Battery & CablesDisconnect the connector from the wires of the fuel pump Test 21- Check 14 AMP FuseNot Activated Test 24 Check START-STOP SwitchTest 27 Check Starter Motor Test 26- Test Starter ContactorConditions Affecting Starter Motor Performance Pinion Checking the PinionTools for Starter Performance Test Measuring CurrentTachometer Testing Starter MotorTest Bracket Starter motor test bracket may be made as shown in FigureTest 30 Check Wire Test 29 Check Wire 14 Power SupplyIf Wire 18 checks GOOD, proceed to Problem 8 Section 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 Adjust the regulated pressure on the gauge to 80 psi If fuel is noted, proceed to next step in flowchartDown Test / Compression Test 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 Belt Tensioning RE-ASSEMBLYFAN Belt Line Corner UP Between 5˚ to 10˚Section Exploded Views / Part Numbers Stator Assembly Rotor AssemblyFlywheel Assembly Bearing Carrier, FrontBase Frame Drawing No D2357-A Door, Service Front Door, Service RearBase Frame Weldment Slide Latch FlushEnclosure Drawing No D2358-D Cover, Access Electrical Cover, Access LiftGasket, Electrical Access Decal, Battery +Views / Part Cover Plate, Scroll Weldment 25 26 Assembly Marine Control Board Assembly, Potted RegulatorRectifier, Battery Charging Wire Assembly #Intake and Exhaust System Drawing No D2362-B Chamber Air Intake Exhaust GasketAir Filter Hose, Air InletViews / Part Numbers Boot, Battery Cable Fuel Pump AssemblyCable, Battery Wire Assembly, Black #4 GroundCustomer Controls Assembly Drawing No D2364-D Switch, Pushbutton Spst Start / Stop SwitchBoot / Nut / Preheat Switch Boot, Circuit BreakerCamshaft Gear Camshaft AssemblyKEY Gear2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B Spring Idler Gear AssemblyThrust Washer OIL Pump CoverIncludes ALL Components Shown below Rocker ARM AssemblyIntake Rocker ARM 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 Generator Specifications Engine SpecificationsType Quietpact Model ROTOR/STATOR Resistance ValuesPage Data Data Electrical Data C4945 Schematic Drawing No C4945-A ModelC4946-A ElectricalSheet 2 OF4996 REV. 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