Guardian Technologies 4270 manual Sheet 2

Page 99

		FUNC TION	W IRE #'s
BLAC K		AC /MISC	11A,13,44A,157 (#10)
					4
					1
LEGEN D				CLOSEST TO BEAR ING
LEGEN D
B CR -	BA TTER Y C H A RGER RECTI FIER
B H 1 -	B U LK	H EA D CO NN ECTOR		, RECEPT	A C LE (B LA C K)
B H 1A -	B U LK	H EA D CO NN ECTOR		, P LU G	(B LA C K)
B H 2A -	B U LK	H EA D CO NN ECTOR , P LU G			(GRAY )
C B1 -	CIRCUIT B RE A K ER		35A		1

4

22

11

6

2

66 44 11 22

55

55

R1

0

18

17

44

11

22

33

0

4

22

6 2

66

33 11

0

0

14

G N D 4

SW 1

Wiring Diagram – Drawing No


CO NN1 -			CUSTOMER REMOTE CO			NN ECTIO N
D1	-	DIODE		600 V, 6A MP
D2	-	DIODE		600 V, 6A MP
FP	-	FUE L PUMP
FS	-	FUE L SO LEN OID
GN D2-			FRA ME STUD
GN D3-			GROU N D (B EA RIN G C A RRIER)
GN D4-			TH RU	B O LT (CO N TRO L P AN EL)
GN D6-			GROU N D STUD		(SE A LED COMP )
H W T	-		H IGH	W A TER TEMP S		W ITCH
H M	-		H OURMETER
LOS	-	LO W OIL PRESSURE S				W ITCH
PH C	-		PRE H EA T CO N TA CTOR
R1	-	RESISTOR , 1 ohm 25W
SC	-		ST A RT CO N TA CTOR
SM	-		ST A RTER MOTOR
SW 2		-	PRE H EA T S W ITCH
TS	-	TERMI NA L STRIP
			CUSTOMER CO		NN ECTIO N

85

1
0	1
GN D3
	17	11
13	150
0	17	11
0

LOS

13

0

11

1

0

18

0

150

85

85

B H 2

1

2

6

14

150

150

14

ENGINE CONTROL

C O MPAR T ME NT

44

22

17

18

15

CO NN1

44

22

14

					1 0
					11
					1	1
					2
		B H 1A				B H 1
11
					C B1		C B1A
					C B1		C B1A
18
18
17
15
1
15					11A		33 A
14					11A		33 A
14
14
150	15	14	17	18	14

150

13

	JUMP ER	15	13
		CONTROL
		PAN EL
		15	F1
33	11	15	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	T1	T2 T2 T3
22

. 0C4946-A (2 of 2) Models 04270-0 Dual

			0	B H 2A
	0		0
		14		14
FP	14	FS		150
	14	FS
				56
			0	0
	16
	SM			157
		13
	RED	0		0
	GN D1			GN D2

12V BA TTER Y CO NN ECTIO N CUSTOMER PROVIDED

11

14

D1

	7
14	14
56
15	14

G N D 6

15

18

11

022

366

44

22

14

15

14

	17
	18
	2
15
2
B CR	GN D5
	162

22

44

0

14

R2

0

1

11

22

4

6

11	6
162	V OLTAGE REGULATO R

COMPAR TMENT

DPE

A VR

120VAC 35A Output

ELECTRICAL

Page 97

GLO W P LU GS

SHEET 2 OF 2

WIRE DIAGRAM, 1.0L DSL	C4946-A
DUAL 120VAC, 35A OUTPUT

Section 11 DATA

Image 99

Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents 57-59 Magnetism Electromagnetic FieldsElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemLine Breakers 120 VAC only 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 AC Frequency Measuring CurrentMeasuring Resistance Ohms LAW Electrical UnitsIntroduction Operational AnalysisCircuit CONDITION- OFF 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 11- Check Rotor Assembly Tance Tests ProcedureTest 10 Check Brushes & Slip Rings Test 14- Check Load Watts & Amperage Test 15 Check Battery Charge OutputTest 12 Check Main Circuit Breaker Test 13- Check Load Voltage FrequencyTest 16 Check Battery Charge Rectifier Battery Charge Rectifier BCR is a full wave rectifierShort to Ground 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 SwitchTest 26- Test Starter Contactor Test 27 Check Starter MotorConditions Affecting Starter Motor Performance 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 32- Test Preheat Contactor Test 33- Test Glow PlugsTest 34- Test D1 Diode Test 35- Check Valve Adjustment Remove the valve cover from engine Disconnect the batteryTest 36- Fuel Injector Pump 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 38 Check OIL Pressure Switch Test 40- Test Water Temperature SwitchTest 39- Check Circuit Board for Ground Test 43 Check Wire 15 for Short to Ground If continuity is measure, replace the switchComponents for Short to Ground 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