Guardian Technologies 4582 & 4987 Testing ALL Stator Windings to Ground, Test Between Windings

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Section 3

DESCRIPTION & COMPONENTS

or DPE winding, (c) a center tapped battery charge winding and (d) a 10 Amp center tapped battery charge winding. Insulation tests of the stator con- sist of (a) testing all windings to ground, (b) testing between isolated windings, and (c) testing between parallel windings. Figure 3-9 is a pictorial representa- tion of the various stator leads on units with air-cooled engine.

TESTING ALL STATOR WINDINGS TO GROUND:

1.Disconnect stator output leads Wire 11 and Wire 44 from the generator 50A circuit breaker.

2.Remove stator output lead Wire 22 from the neutral terminal on the back of the 50A outlet.

3.Disconnect the C1 connector from the bottom of the control panel. See Figure 3-10. The C1 connector is on the right when facing the control panel.

11

44

22

11S

44S

55A

66A

77A

2

6

55

66

77

Figure 3-9. – Stator Winding Leads

4.Connect the terminal ends of Wires 11, 22, and 44 together. Make sure the wire ends are not touching any part of the gen- erator frame or any terminal.

5.Connect the red test probe of the Hi-Pot tester to the joined terminal ends of stator leads 11, 22, and 44. Connect the black tester lead to a clean frame ground on the stator can. With tes- ter leads connected in this manner, proceed as follows:

a.Turn the Hi-Pot tester switch OFF.

b.Plug the tester cord into a 120 volt AC wall sock- et and set its voltage selector switch to “1500 volts”.

c.Turn the tester switch ON and observe the breakdown lamp on tester. DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. After one (1) second, turn the tester switch OFF.

If the breakdown lamp comes on during the one-sec- ond test, the stator should be cleaned and dried. After cleaning and drying, repeat the insulation test. If, after

cleaning and drying, the stator fails the second test, the stator assembly should be replaced.

6.Now proceed to the C1 connector ( Female side – Just removed). Each winding will be individually tested for a short to ground. Insert a large paper clip (or similar item) into the C1 connector at the following pin locations:

Pin

Wire

Winding

Location

Number

 

1

11S

Sense Lead Power

 

 

 

2

44S

Sense Lead Power

 

 

 

3

55A

Battery Charge

 

 

 

4

66A

Battery Charge

 

 

 

5

77A

Battery Charge

 

 

 

6

2

Excitation

 

 

 

7

6

Excitation

 

 

 

8

55

10 Amp Battery Charge

 

 

 

9

66

10 Amp Battery Charge

 

 

 

10

77

10 Amp Battery Charge

 

 

 

11

4

(Positive lead to Brush)

 

 

 

12

0

(Negative lead to Brush)

 

 

 

Next refer to Steps 5a through 5c of the Hi-Pot proce- dure.

Example: Insert paper clip into Pin 1, Hi-Pot from Pin 1 (Wire 11S) to ground. Proceed to Pin 2, Pin 3, etc. through Pin 10.

 

77A

55A

 

11S

PIN

 

 

66A

 

 

PIN

2

44S

 

LOCATION

LOCATION

1

 

6

 

PIN

 

 

 

 

PIN

 

55

77

0

LOCATION

LOCATION

 

12

 

 

 

7

6

 

66

4

 

Figure 3-10. – C1 Connector Pin Location Numbers (Female Side, Located to the Right When Facing the Control Panel)

TEST BETWEEN WINDINGS:

1.Insert a paper clip into Pin Location 3 (Wire 55A). Connect the red tester probe to the paper clip. Connect the black tes- ter probe to Stator Lead 11. Refer to Steps 5a through 5c of

“TESTING ALL STATOR WINDINGS TO GROUND”.

2.Repeat Step 1 at Pin Location 6 (Wire 2) and Stator Lead 11.

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Disassembly and Exploded Views 66-71 Electromagnetic Fields MagnetismElectromagnetic Induction Simple AC Generator STATORs AC power windingsMore Sophisticated AC Generator Generator Operating Diagram Meters Measuring AC VoltageVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawIntroduction AC Generator Rotor AssemblyEngine-Generator Drive System Stator Assembly Brush Holder and BrushesOther AC Generator Components Excitation Circuit Breaker162 Underfrequency AdjustVoltage Regulator Field Boost Circuit Rotor Residual MagnetismOperation Megohmmeter Insulation ResistanceStator Insulation Resistance Test Testing ALL Stator Windings to Ground Test Between WindingsRotor Insulation Resistance Test Cleaning the GeneratorDrying the Generator Battery Recommended BatteryPrinted Circuit Board Circuit Board ConnectionsControl Panel Component Identification ENGINE DC CONTROLC2 Female Side C2 Male Side C1 Female Side C1 Male SideTerminal Block Terminal BLOCKTB2 TB1 Page Circuit Condition Rest = 12 VDC Control Circuit Condition Start IM1 SP1 IM2 SP2 RED Black Battery Circuit Condition RUN = Idle Control Transformer Output CIRcUIT Condition Stop Fault Shutdown Problem 1 Voltage & Frequency Are Both High or Low If Problem Involves AC OutputIntroduction Or Replace If BAD Load Watts Problem 4 No Battery Charge Output Problem 5 No 10A Battery Charge OutputProblem 6 Engine Will Not Crank Problem 7 Engine Cranks But Will Not Start Problem 8 Engine Starts Hard and Runs Rough Problem 9 Engine Starts Then Shuts DownProblem 10 10 Amp Fuse F1 Blowing Problem 12 Idle Control RPM Does Not Decrease Problem 11 Unit OverspeedsProblem 14 Engine Hunts / Erratic Idle Procedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Main Circuit Breaker ResultsIf circuit breaker is good, go on to Test Test 4 Fixed Excitation Test Rotor AMP DrawSet voltmeter to measure AC voltage AC Voltage across Wires 11S and 44S= Refer to Test 4 Results chartRemove air cleaner cover to access stepper motor Set a voltmeter to measure resistanceTest 6 Wire Continuity Test 7 Check Field BoostDisconnect both wires from the Resistor R1 Test 8 DIODE/RESISTORSet volt meter to the diode test range Set volt meter to measure resistanceFrom the 50 Amp receptacle disconnect Wire Test 9 Test StatorUnplug the six pin connector at the Voltage Regulator Test 10 Sensing LeadsTest 11 Excitation Wiring Gain access to the brushes and slip ringsTest 12 Check Brush Leads Test 13 Check Brushes & Slip RingsTest 14 Check Rotor Assembly Test 15 Check Load Voltage FrequencyTest 16 Check Load Watts & Amperage If the unit is overloaded, reduce the loadTest 19 Check Battery Charge Rectifier BCR2 Test 17 Check Battery Charge OutputDisconnect all wires from the Battery Charge Rectifier Test 21- Check 10 Amp Fuse Test 22- Check Battery & CablesBCR1BCR2 Refer back to flow chart Test 23 Check Voltage at Starter Contactor SCTest 24 Check Starter Contactor SC Test 25 Check Starter MotorChecking the Pinion Tools for Starter Performance TestTest 26 Test Starter Contactor Relay SCR Set voltmeter to measure DC voltageTest 27 Check Start-Run-Stop Switch SW1 Test 28 Check Start-Run-Stop Switch SW1 WiringReconnect all wires to the switch Procedure Set voltmeter to measure resistanceTest 29 Check Ignition Spark Refer back to the Flow ChartTest 30 Check Spark Plugs Test 31 Remove Wire 18 / Shutdown Lead Refer to Flow ChartSSR and the Battery Charge Rectifier 2 BCR2 Test 32 Test Start Stop Relay SSRTest 33 Test Wire RUNTest 35 Check and Adjust Ignition Test 34 Test Start Stop Relay WiringMagnetos Test 36 Test Fuel Shutoff Solenoid FSS Test 37 Test Fuel Shutoff Solenoid VoltageTest 38 Check Fuel Pump MagnetoAdjusting Valve Clearance Test 40 Valve AdjustmentTest 39 Check Carburetion Adjust the regulated pressure on the gauge to 80 psi 52 Tightening the Jam NutTest 42 Check Oil Pressure Switch Wire Test 43 Check Start Stop Relay SSRTest 45 Check Wire 15 Circuit Test 46 Check Wire 14 CircuitTest 44 Test Starter Contactor Relay SCR Test 47 Check Fuel Shutoff SolenoidTest 50 Check Wire Test 49 Check Wire 15BTest 51 Check Wires 11S & 44S Test 48 Check HourmeterTest 52 Check Idle Control Switch Test 53 Check Idle Control WiringSW2 TB2Test 55 Check TR1 & TR2 Wiring Test 54 Check Idle Control Transformers ICTTest 56 Choke Test Continuity should be measuredMajor Disassembly Remove air deflector Figure B, Item #45 from cross memberSupport Alternator 3317 3026 20 22 25 QTY Description Detail of Battery Tray QTY. Description ELECTRICAL DATA RED Battery Charge Winding BA Brush Assembly Governor Actuator 167 229 15B Power Winding DPE Winding SCR Wiring Diagram 17.5 kW Drawing No G0731 Stator Closest to Bearing Electrical Schematic 17.5 kW Drawing No G0733 Circuit 11 ORG Circuit 13 DRK BLU Circuit 15 PNK ELECTRICAL DATA Page Load % Rated Max DC Load Amperes Current @ 12 VoltsFrequency Hz 238-242 59-61 100 Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI

5308, 4583, 4451 & 4986, 4582 & 4987 specifications

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