Guardian Technologies 4270 manual Engine Governor, Fuel Injection Pump, Fuel NOZZLES/INJECTORS

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Section 5

ENGINE DC CONTROL SYSTEM

The positive (+) battery cable (13) attaches to one of the outer posts of the contactor along with Wire 13 for the DC supply to the fuse (F1). The starter cable (16) attaches to the remaining outer post. Attached to the small 2 lugs are Wires 56 and 0. When the start/stop switch is set to start, the circuit board delivers battery voltage to the contactor coil via Wire 56. The contac- tor energizes and its contacts close. Battery voltage is then delivered from the positive battery cable, across contacts and to the starter motor via Wire 16.

ENGINE GOVERNOR

Amechanical, all-speed governor is used on the diesel engine. It is housed in the gear case. A fly- weight movement is transmitted to the injection pump control rack by way of the slider, control lever and link. A spring is attached to the arm and the tension lever. The spring regulates flyweight movement. By changing the set angle of the governor lever, tension on the tension lever spring is changed. In this man- ner, engine speed can be regulated by the governor lever.

The generators A/C output frequency is directly pro- portional to engine speed. Low governor speed will result in a reduced A/C frequency and voltage, and high governor speed will produce an increased fre- quency and voltage.

FUEL INJECTION PUMP

CONTROL RACK

SHIM

INJECTOR PUMP

Figure 5-8. – Fuel Injection Pump

The fuel injection pump is mounted on the side of the engine and rides on a three-lobe camshaft. The lobes on the camshaft press the bottom of the pump, which mechanically opens the fuel path to deliver fuel to the fuel injectors. Timing for the fuel injector pump is determined by the distance between the camshaft lobes and the pump. This distance is regulated by metal shims. If the shim space is incorrect, the fuel pressure will be incorrect and combustion will not occur. When the fuel injector pump is removed for maintenance, be sure to reassemble with the same number of shims. The engine governor controls the fuel injector pump by linkage connecting the two.

FUEL NOZZLES/INJECTORS

Fuel supplied by the injector pump is delivered to the nozzle holder and to the nozzle body. When fuel pressure is sufficient to compress the spring, fuel is supplied from the nozzle and into the combustion chamber. Due to the high pressure of fuel being ejected from the nozzle, there is no safe test. If faulty fuel is suspected and a clogged injector pump was diagnosed, the replacement of the injector nozzles would be needed.

INJECTOR

CAP

INSERT

GASKET

Figure 5-9. – Fuel Injectors

 

VALVE

VALVE

FULLY

CLOSED

OPEN

OPEN

Figure 5-10. – Fuel Injector Nozzles

GLOW PLUGS

The glow plug consists of a thin coiled heat-wire that is encased in sintered magnesium oxide powder and enclosed by a stainless steel sheath. One end of the wire is welded to the sheath and the other end is welded to the center electrode. When voltage is applied to the center electrode, it heats the heat-wire, which in turn, heats the combustion chamber.

Glow plugs are connected in parallel. For that rea- son, if one plug fails open, the other plugs will contin- ue to operate. However, loss of one plug will increase the possibility of the heat-wire melting open in the remaining plugs.

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents 57-59 Electromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Line Breakers 120 VAC only Field BoostGenerator AC Connection System 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 Resistance Measuring AC FrequencyMeasuring Current Ohms LAW Electrical UnitsCircuit CONDITION- OFF IntroductionOperational Analysis 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 184WTest 10 Check Brushes & Slip Rings Test 11- Check Rotor AssemblyTance Tests Procedure Test 12 Check Main Circuit Breaker Test 15 Check Battery Charge OutputTest 13- Check Load Voltage Frequency Test 14- Check Load Watts & AmperageShort to Ground Test 16 Check Battery Charge RectifierBattery Charge Rectifier BCR is a full wave rectifier 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 SwitchConditions Affecting Starter Motor Performance Test 26- Test Starter ContactorTest 27 Check Starter Motor 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 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 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 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 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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