Guardian Technologies 4583 Problem 11 Unit Overspeeds, Problem 14 Engine Hunts / Erratic Idle

Page 38

Section 5

TROUBLESHOOTING FLOWCHARTS

Problem 11 - Unit Overspeeds

TEST 1 - CHECK

NO-LOAD VOLTAGE

& FREQUENCY

NO

VOLTAGE

GO TO PROBLEM 2

PRODUCING

VOLTAGE

 

CHECK TO SEE IF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RED LED ON

 

 

ON

 

 

 

 

CIRCUIT BOARD IS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

“ON”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TEST 51 - CHECK

 

 

 

 

 

 

 

 

GOOD

 

 

 

WIRES 11S / 44S

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TEST 5 - CHECK

 

 

 

REPLACE

GOOD

 

STEPPER MOTOR

 

 

CIRCUIT

 

 

OPERATION

 

 

 

BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BAD

 

 

 

 

 

 

 

 

 

 

 

 

BAD REPAIR OR REPLACE

Problem 12 - Idle Control “RPM Does Not Decrease”

VERIFY THAT

THERE IS NO LOAD

ON THE

GENERATOR

TEST 52 - CHECK

IDLE CONTROL

SWITCH

BAD

REPLACE

 

 

 

TEST 53 - CHECK

 

 

 

REPLACE PRINTED

 

 

GOOD

 

GOOD

 

 

IDLE CONTROL

 

 

 

 

 

 

CIRCUIT BOARD

 

 

 

WIRING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BAD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REPAIR OR REPLACE

 

 

 

Problem 13 - Idle Control “RPM Does Not Increase When Load Is Applied”

VERIFY THAT WIRE 11 & WIRE 44 ARE ROUTED THROUGH IDLE CONTROL TRANSFORMERS (ICT)

ROUTE THROUGH IDLE

CONTROL TRANSFORMERS

AND RE-TEST

GOOD

TEST 54 - CHECK

IDLE CONTROL

TRANSFORMERS

(ICT)

BAD

REPLACE

 

 

 

TEST 55 - CHECK

 

 

 

REPLACE

GOOD

 

 

 

 

 

 

GOOD

 

 

 

TR1 & TR2

 

 

PRINTED

 

 

 

 

 

 

WIRING

 

 

 

CIRCUIT BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BAD

REPAIR OR REPLACE

Problem 14 - Engine “Hunts” / Erratic Idle

*Acceptable running limits for the engine are between 59-61 Hertz.

TEST 56 - CHOKE

TEST

NO

SURGING

TEST 39 - CHECK

CARBURETION

STILL

SURGING

TEST 40 - CHECK /

ADJUST VALVES

BAD

ADJUST / RE-TEST

GOOD

GOOD

TEST 29 - CHECK

SPARK

GOOD

TEST 30 - CHECK

SPARK PLUG

BAD - ENGINE MISS

APPARENT

TEST 35 - CHECK /

ADJUST IGNITION

MAGNETOS

REPLACE

 

 

 

TEST 5 - CHECK

PRINTED

 

GOOD

 

STEPPER MOTOR

 

 

CIRCUIT BOARD

 

 

 

OPERATION

 

 

 

 

 

 

 

 

REPAIR

OR BAD

REPLACE

BAD

REPLACE

BAD

ADJUST OR REPLACE

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Page 37 Page 39
Image 38
Page 37 Page 39
Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Disassembly and Exploded Views 66-71 Electromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator STATORs AC power windingsSimple AC Generator Generator Operating Diagram VOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawEngine-Generator Drive System Rotor AssemblyIntroduction AC Generator Other AC Generator Components Stator AssemblyBrush Holder and Brushes Excitation Circuit BreakerVoltage Regulator Underfrequency Adjust162 Operation Rotor Residual MagnetismField Boost Circuit Stator Insulation Resistance Test Insulation ResistanceMegohmmeter Testing ALL Stator Windings to Ground Test Between WindingsDrying the Generator Cleaning the GeneratorRotor Insulation Resistance Test Printed Circuit Board BatteryRecommended Battery Circuit Board ConnectionsControl Panel Component Identification ENGINE DC CONTROLTerminal Block Terminal BLOCKTB2 TB1 C1 Female Side C1 Male SideC2 Female Side C2 Male Side 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 Introduction If Problem Involves AC OutputProblem 1 Voltage & Frequency Are Both High or Low 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 14 Engine Hunts / Erratic Idle Problem 11 Unit OverspeedsProblem 12 Idle Control RPM Does Not Decrease Test 2 Check Main Circuit Breaker ProcedureTest 1 Check No-Load Voltage Frequency ResultsSet voltmeter to measure AC voltage Test 4 Fixed Excitation Test Rotor AMP DrawIf circuit breaker is good, go on to Test 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 BoostSet volt meter to the diode test range Disconnect both wires from the Resistor R1Test 8 DIODE/RESISTOR 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 12 Check Brush Leads Test 11 Excitation WiringGain access to the brushes and slip rings Test 13 Check Brushes & Slip RingsTest 16 Check Load Watts & Amperage Test 14 Check Rotor AssemblyTest 15 Check Load Voltage Frequency If the unit is overloaded, reduce the loadDisconnect all wires from the Battery Charge Rectifier Test 17 Check Battery Charge OutputTest 19 Check Battery Charge Rectifier BCR2 BCR1BCR2 Test 22- Check Battery & CablesTest 21- Check 10 Amp Fuse Test 24 Check Starter Contactor SC Refer back to flow chartTest 23 Check Voltage at 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 voltageReconnect all wires to the switch Test 27 Check Start-Run-Stop Switch SW1Test 28 Check Start-Run-Stop Switch SW1 Wiring Procedure Set voltmeter to measure resistanceTest 30 Check Spark Plugs Refer back to the Flow ChartTest 29 Check Ignition Spark SSR and the Battery Charge Rectifier 2 BCR2 Test 31 Remove Wire 18 / Shutdown LeadRefer to Flow Chart Test 32 Test Start Stop Relay SSRTest 33 Test Wire RUNMagnetos Test 34 Test Start Stop Relay WiringTest 35 Check and Adjust Ignition Test 38 Check Fuel Pump Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage MagnetoTest 39 Check Carburetion Test 40 Valve AdjustmentAdjusting Valve Clearance 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 44 Test Starter Contactor Relay SCR Test 45 Check Wire 15 CircuitTest 46 Check Wire 14 Circuit Test 47 Check Fuel Shutoff SolenoidTest 51 Check Wires 11S & 44S Test 50 Check WireTest 49 Check Wire 15B Test 48 Check HourmeterSW2 Test 52 Check Idle Control SwitchTest 53 Check Idle Control Wiring 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 Frequency Hz 238-242 59-61 100 Rated Max DC Load Amperes Current @ 12 VoltsLoad % Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI

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