Guardian Technologies 4270 manual Engine Control Circuit Board, Battery

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Section 5

ENGINE DC CONTROL SYSTEM

ENGINE CONTROL CIRCUIT BOARD

GENERAL:

The ENGINE CONTROL circuit board is responsible for cranking, startup, running, and shutdown opera- tions. The board interconnects with other components of the DC control system to turn them on and off at the proper times. It is powered by fused 12 VDC power from the unit battery.

CIRCUIT BOARD CONNECTIONS:

The circuit board mounts two, six-wire terminal strips. They are labeled 1-6 and 7-12.

OVERSPEED SHUTDOWN POTENTIOMETER:

The overspeed shutdown potentiometer is used to set the frequency at which the board will initiate a engine shutdown. Proper setting of the potentiometer is criti- cal to the correct operation of the generator.

ADJUSTMENT PROCEDURE:

The overspeed shutdown potentiometer MUST be adjusted on replacement circuit boards.

If not replacing a board, start at STEP 6.

1.Remove 14 amp fuse (F1) from control panel.

2.Disconnect all wires from circuit board terminals.

The following chart shows the associated wires and the function(s) of each terminal and wire.

TERMINAL

WIRE

FUNCTION

1

15

Power supply (12VDC) for the circuit board

 

 

and DC control system.

 

 

 

2

0

Common Ground

3

17

To Start Stop Switch and remote connector.

 

 

When grounded by setting Start-Stop

 

 

Switch to "START", engine will crank.

 

 

 

4

18

To Start-Stop Switch and remote connector.

 

 

When grounded by setting Start-Stop-

 

 

Switch to "STOP", engine shuts down.

 

 

 

5

44

Frequency signal for overspeed

 

 

shutdown/starter disengage.

 

 

 

6

22

Frequency signal for overspeed

 

 

shutdown/starter disengage.

7

56

Delivers 12 VDC to Starter Contactor (SC)

 

 

while cranking only.

8

__

Not Used

9

14

Engine run circuit. Delivers 12 VDC during

 

 

cranking and running.

 

 

Connected to Fuel Pump, Fuel Solenoid,

 

 

Hourmeter, and field boost circuit.

 

 

 

10

14

Engine run circuit. Delivers 12 VDC during

 

 

cranking and running.

 

 

Connected to Fuel Pump, Fuel Solenoid,

 

 

Hourmeter, and field boost circuit.

 

 

 

11

14

Engine run circuit. Delivers 12 VDC during

 

 

cranking and running.

 

 

Connected to Fuel Pump, Fuel Solenoid,

 

 

Hourmeter, and field boost circuit.

1285 Fault shutdown circuit. When grounded by High Water Temperature or Low Oil Pressure switch, engine will shut down.

LED FUNCTIONS:

Green LED will be illuminated when Wire 14 is ener- gized during cranking and running.

Red LED will be illuminated when Wire 56 is ener- gized during cranking only.

3.Remove old circuit board and install new circuit board.

4.Connect all wires to proper circuit board terminals. Follow elec- trical schematic if needed.

5.Reinstall 14 amp (F1) fuse into control panel.

6.Turn the overspeed shutdown potentiometer slowly counter- clockwise until it stops. DO NOT FORCE.

Note: If immediate shutdown occurs when the engine starts and the START/STOP switch is released, reverse overspeed shutdown pot set- ting, turn pot clockwise and proceed. In Step 10 and Step 11, turn the overspeed shutdown pot counterclockwise.

7.Connect an accurate AC frequency meter across the genera- tor's AC output leads.

8.Start the generator, let it stabilize and warm up.

9.Use the injection throttle lever to SLOWLY increase engine speed until the frequency meter reads 64 hertz.

10.Hold the throttle at 64 hertz and SLOWLY turn the overspeed shutdown potentiometer clockwise until engine shutdown occurs.

11.Turn the overspeed shutdown potentiometer clockwise an additional 1/8 turn. The overspeed setting is now correct.

BATTERY

RECOMMENDED BATTERY:

When anticipated ambient temperatures will be con- sistently above 32° F. (0° C.), use a 12 VDC automo- tive type storage battery rated 70 amp-hours and capable of delivering at least 360 cold cranking amperes.

The QUIETPACT 75D generator is rated at about 160 DC Amps of cranking current to operate the starter and glow plugs.

BATTERY CABLES:

Use of battery cables that are too long or too small in diameter will result in excessive voltage drop. For best cold weather starting, voltage drop between the

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents 57-59 Electromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Line Breakers 120 VAC only Field BoostGenerator AC Connection System Connection for 120/240 VAC Dual Voltage Rotor Assembly LIC Grit or Abrasive to Clean Slip RingsExcitation Circuit Components Battery Charge ComponentsBrush Holder General162 Adjust POT LEDAdjustment Procedure Voltage RegulatorControl Panel Component Identification Control Panel ComponentsDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersCloth or Compressed AIR Brushing and Vacuum CleaningStator Insulation Resistance Stator SHORT-TO-GROUND TestsTesting Rotor Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Resistance Measuring AC FrequencyMeasuring Current Electrical Units Ohms LAWCircuit CONDITION- OFF IntroductionOperational Analysis Circuit CONDITION- PRE-HEAT Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Circuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdowns Battery Engine Control Circuit BoardCharging a Battery Effects of TemperatureChecking Battery State of Charge Adding WaterAMP Fuse Preheat SwitchSTART/STOP Switch Starter Contactor & MotorFuel NOZZLES/INJECTORS Engine GovernorFuel Injection Pump Glow PlugsEngine Protective Devices LOW OIL Pressure Switch High Coolant Temperature SwitchAdapter LOW OIL Pressure Switch Overspeed ProtectionTroubleshooting 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 FrequencyTest 3- Test Excitation Circuit Breaker Test 4- Fixed Excitation TEST/ROTOR AMP DrawTest 6- Check Field Boost Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Set a VOM to its Rx1 scaleTest 7 Test Stator DPE Winding Model QP75D159W Test 8- Check Sensing Leads / Power WindingsTest 9- Check Brush Leads 184WTest 10 Check Brushes & Slip Rings Test 11- Check Rotor AssemblyTance Tests Procedure Test 13- Check Load Voltage Frequency Test 15 Check Battery Charge OutputTest 12 Check Main Circuit Breaker Test 14- Check Load Watts & AmperageShort to Ground Test 16 Check Battery Charge RectifierBattery Charge Rectifier BCR is a full wave rectifier Test 18 TRY Cranking the Engine Test 19- Test PRE-HEAT SwitchSet a VOM to read battery voltage 12 VDC Test 20- Check Fuel PumpDisconnect 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 FuseTest 24 Check START-STOP Switch Not ActivatedConditions Affecting Starter Motor Performance Test 26- Test Starter ContactorTest 27 Check Starter Motor Tools for Starter Performance Test Checking the PinionPinion Measuring CurrentTest Bracket Testing Starter MotorTachometer Starter motor test bracket may be made as shown in FigureIf Wire 18 checks GOOD, proceed to Problem 8 Section Test 29 Check Wire 14 Power SupplyTest 30 Check Wire Test 28- Check Fuel SupplyTest 34- Test D1 Diode Test 32- Test Preheat ContactorTest 33- Test Glow Plugs Test 36- Fuel Injector Pump Test 35- Check Valve AdjustmentRemove the valve cover from engine Disconnect the battery 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 cylinderTest 39- Check Circuit Board for Ground Test 38 Check OIL Pressure SwitchTest 40- Test Water Temperature Switch Components for Short to Ground Test 43 Check Wire 15 for Short to GroundIf continuity is measure, replace the switch Major Disassembly RE-ASSEMBLY Belt TensioningLine Corner UP Between 5˚ to 10˚ FAN BeltSection Exploded Views / Part Numbers Flywheel Assembly Rotor AssemblyStator Assembly Bearing Carrier, FrontBase Frame Drawing No D2357-A Base Frame Weldment Door, Service RearDoor, Service Front Slide Latch FlushEnclosure 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 InletViews / Part Numbers Cable, Battery Fuel Pump AssemblyBoot, Battery Cable Wire Assembly, Black #4 GroundCustomer Controls Assembly Drawing No D2364-D Boot / Nut / Preheat Switch Start / Stop SwitchSwitch, Pushbutton Spst Boot, Circuit BreakerKEY Camshaft AssemblyCamshaft Gear Gear2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B Thrust Washer Idler Gear AssemblySpring OIL Pump CoverIntake Rocker ARM Rocker ARM AssemblyIncludes ALL Components Shown below 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 Engine Specifications Generator SpecificationsROTOR/STATOR Resistance Values Type Quietpact ModelPage Data Data Electrical Data Schematic Drawing No C4945-A Model C4945Electrical C4946-ASheet 2 OF4996 REV. O
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