Guardian Technologies 4270 manual Data

Page 95

 

 

FUNCT ION

W IRE

#'s

 

BLAC K

AC /MISC

11A,13,44 A,157 (#10)

A VR -

A U TO M A TIC

VOLTA GE REGUL A TOR

4

BCR - B

A TTERY CH

A RGER REC TIFIER

 

1

 

 

 

 

 

 

BH 1A - BULK HE

A D CONNEC

TOR, PLUG (BL

A CK)

BH 2 - BULK HE

A D CONNEC

TOR, RECEP

TA CLE (GR A Y)

BH 2A - BULK HE

A D CONNEC

TOR, PLUG (GR

A Y)

CB 2

- C IRCU IT BRE A KER

4A

W ITH

RE D(4) L EA D

 

 

 

 

 

BRUSH

 

 

 

 

 

CLOSEST

TO BEAR ING

D2

- D IODE

600 V, 6A M P

 

 

F1

-

FU SE

14A M P SFE

 

 

1

FP

-

FUEL PU M P

 

 

 

 

 

FS

-

FUEL

SOLENO ID

 

 

 

GND 1- ENG INE GROUND

 

 

 

GND 2-

FRA M E

STUD

 

 

 

GND 4-

THRU BOL T (CON TROL P A NEL)

 

 

GND 5- GROUND

STUD (NON- SEA LED CO M P)

 

GND 6- GROUND

STUD ( SEA LED CO M P)

 

 

H M

- HOUR

M ETER

 

 

 

LOS

- LO W

O IL PRE SS URE

SW ITCH

 

 

PHC - PREHE

 

A T CON TA C TOR

 

1

 

 

 

R1

- RE SISTOR, 1 ohm

25W

 

 

R2

- RE SISTOR 20 ohm , 12W

 

 

SC

-

STA RT CON TA C TOR

 

 

SW 1 -

SW ITCH

STA RT/ STOP

 

 

SW 2

- PREHE

A T SW ITCH

 

0

1

TS

-

TER M IN A L STRIP

 

0

 

 

CU STO M ER CONNEC

TION

 

 

0

 

GND 3

 

 

 

 

14

 

 

 

 

0

 

 

17

11

 

 

 

 

 

 

85

 

13

150

 

 

 

 

 

 

 

 

0

 

17

11

 

 

 

 

 

 

 

LOS

 

 

 

 

 

 

0

BH 2A

 

 

0

 

 

 

 

 

14

 

14

 

F

14

FS

 

150

 

 

 

 

 

 

 

 

 

56

4

22

11

6

2

66 44 11 22

55

55

R1

0

18

17

13

0

11

 

 

1

 

 

0

 

18

0

 

 

150

 

85

 

 

 

BH 2

1

2

6

 

 

11

 

 

7

 

14

14

 

56

 

44

11

22

33

0

14

14

150

44

22

17

18

15

11

18

17

15

1

15

14

14

150

14

CONN 1

150

 

EN GINE CONTRO L

COMPARTMENT

44 22

14

14

D1

66

15

 

 

1 0

 

 

 

 

 

11

 

 

1 2

 

 

BH 1A

BH 1

 

 

CB 1

 

CB 1A

 

 

 

 

 

 

 

 

11A

33 A

15

14

17

18

14

17

18

2

1

4

22

6

2

66

33

11

0

0

 

 

GND 4

 

 

 

 

SW 1

 

150

 

 

 

13

 

 

 

JUMPER

15

13

 

CONTRO

L

 

 

PANE L

 

 

 

 

15

F1

33

11

150

11

33

66

77

4

11

22

11

33

15

1 0

1

33A 11A

 

11A

33 A

 

 

0

44

T1 T2

T2 T3

TS

22

 

 

 

0

 

 

14

 

 

R2

 

0

 

 

Wiring Diagram – Drawing No. 0D2793-B (2 of 2) Models 04270-1 & 04270-2 Dual

 

0

0

16

 

 

SM

 

157

 

13

 

RED

0

0

GND 1

 

GND 2

12V B A TTERY CONNEC

TION

 

CU STO M ER PRO VIDED

 

 

15

 

 

 

 

 

 

CB 2

14

 

 

 

 

 

 

 

 

 

 

 

3

2

1

 

GND 6

15

 

 

 

 

GND 5

 

 

 

 

 

BCR

 

 

 

 

 

 

 

 

18

44

22

14

 

 

 

11

162

0

22

 

 

22

 

 

 

 

44

 

 

15

 

 

14

 

1

 

11

 

22

 

4

 

6

11

6

162 V OLTA GE RE GULATOR

COMPARTMENT

DPE

A VR

120VAC 35A Output

ELECTRICAL

Page 93

GLO W PLUG S

SH EET 2 OF 2

WIRE DIAGRAM, 1.0L DSL

04270-1

 

SINGLE 120/240VAC OUTPUT

0D2793-B

Section 11 DATA

Image 95
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 AssemblyGeneral Battery Charge ComponentsBrush Holder Excitation Circuit ComponentsVoltage Regulator Adjust POT LEDAdjustment Procedure 162Control Panel Components Control Panel Component IdentificationInsulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the GeneratorStator SHORT-TO-GROUND Tests Brushing and Vacuum CleaningStator Insulation Resistance Cloth or Compressed AIRMegohmmeter Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC 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 BatteryAdding Water Effects of TemperatureChecking Battery State of Charge Charging a BatteryStarter Contactor & Motor Preheat SwitchSTART/STOP Switch AMP FuseGlow Plugs Engine GovernorFuel Injection Pump Fuel NOZZLES/INJECTORSOverspeed Protection LOW OIL Pressure Switch High Coolant Temperature SwitchAdapter LOW OIL Pressure Switch Engine Protective DevicesTroubleshooting 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 BreakerSet a VOM to its Rx1 scale Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Test 6- Check Field BoostModel QP75D Test 7 Test Stator DPE Winding184W Test 8- Check Sensing Leads / Power WindingsTest 9- Check Brush Leads 159WTest 10 Check Brushes & Slip Rings Test 11- Check Rotor AssemblyTance Tests Procedure Test 14- Check Load Watts & Amperage Test 15 Check Battery Charge OutputTest 12 Check Main Circuit Breaker Test 13- Check Load Voltage FrequencyShort to Ground Test 16 Check Battery Charge RectifierBattery Charge Rectifier BCR is a full wave rectifier Test 20- Check Fuel Pump Test 19- Test PRE-HEAT SwitchSet a VOM to read battery voltage 12 VDC Test 18 TRY Cranking the EngineTest 21- Check 14 AMP Fuse Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board Disconnect the connector from the wires of the fuel pumpNot Activated Test 24 Check START-STOP SwitchConditions Affecting Starter Motor Performance Test 26- Test Starter ContactorTest 27 Check Starter Motor Measuring Current Checking the PinionPinion Tools for Starter Performance TestStarter motor test bracket may be made as shown in Figure Testing Starter MotorTachometer Test BracketTest 28- Check Fuel Supply Test 29 Check Wire 14 Power SupplyTest 30 Check Wire If Wire 18 checks GOOD, proceed to Problem 8 SectionTest 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 Repeat Steps 1 through 8 on remaining cylinder If fuel is noted, proceed to next step in flowchartAdjust the regulated pressure on the gauge to 80 psi Down Test / Compression TestTest 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 Bearing Carrier, Front Rotor AssemblyStator Assembly Flywheel AssemblyBase Frame Drawing No D2357-A Slide Latch Flush Door, Service RearDoor, Service Front Base Frame WeldmentEnclosure Drawing No D2358-D Decal, Battery + Cover, Access LiftCover, Access Electrical Gasket, Electrical AccessViews / Part Cover Plate, Scroll Weldment 25 26 Wire Assembly # Assembly, Potted RegulatorAssembly Marine Control Board Rectifier, Battery ChargingIntake and Exhaust System Drawing No D2362-B Hose, Air Inlet Exhaust GasketChamber Air Intake Air FilterViews / Part Numbers Wire Assembly, Black #4 Ground Fuel Pump AssemblyBoot, Battery Cable Cable, BatteryCustomer Controls Assembly Drawing No D2364-D Boot, Circuit Breaker Start / Stop SwitchSwitch, Pushbutton Spst Boot / Nut / Preheat SwitchGear Camshaft AssemblyCamshaft Gear KEY2630 Liter Diesel Cylinder Head Drawing No D2794 Liter Diesel Crankshaft, Piston and Flywheel Drawing No -B OIL Pump Cover Idler Gear AssemblySpring Thrust WasherExhaust Rocker ARM Rocker ARM AssemblyIncludes ALL Components Shown below Intake 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. O