Guardian Technologies 5308, 4583 manual Test 1 Check No-Load Voltage Frequency, Procedure, Results

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Section 6

DIAGNOSTIC TESTS

Introduction

The “Diagnostic Tests” in this chapter may be per- formed in conjunction with the “Flow Charts” of Section 5. Test numbers in this chapter correspond to the numbered tests in the “Flow Charts”.

Tests 1 through 19 are procedures Involving problems with the generator's AC output voltage and frequency (Problems 1 through 5 in the “Flow Charts”).

Tests 19 through 54 are procedures involving prob- lems with engine operation (Problems 6 through 14 in the “Troubleshooting Flow Charts”).

It may be helpful to read Section 2, “Measuring Electricity”.

NOTE: Test procedures in this Manual are not nec- essarily the only acceptable methods for diagnos- ing the condition of components and circuits. All possible methods that might be used for system diagnosis have not been evaluated. If any diag- nostic method is used other than the method pre- sented in this Manual, the technician must ensure that neither his personal safety nor the product's safety will be endangered by the procedure or method that has been selected.

Test 1 - Check No-Load Voltage and

Frequency

PROCEDURE:

1.Disconnect or turn OFF all electrical loads connected to the generator.

2.Set a volt meter to measure AC voltage.

3.Reset all circuit breakers to the on position.

4.Turn the Idle Control switch to OFF.

5.Start the engine and let it stabilize and warm up.

50A240

Figure 6-1. – VOM Test Leads Connected to 50A

Outlet

*NOTE: If the generator is not producing AC Power, loss of governor control may occur caus- ing an overspeed or extremely high RPM condi- tion. If this condition occurs manually control throttle (60Hz /3600 RPM) to perform test.

6.Place the meter test leads into the 50A outlet. See Figure 6-1.

7.Read the AC voltage.

8.Connect a AC frequency meter as described in Step 6.

9.Read the AC frequency.

RESULTS:

For units rated 60 Hertz, no load voltage and frequen- cy should be approximately 238-242 VAC and 59-61 Hertz. See Flow Chart Problem 1.

TEST 2 - CHECK MAIN CIRCUIT BREAKER

PROCEDURE:

The generator has seven circuit breakers located on the control panel. If outlets are not receiving power, make sure the breakers are set to ON or “Closed”.

If a breaker is suspected to have failed, it can be tested as follows (see Figure 6-7):

1.Set a Volt meter to measure resistance.

2.With the generator shut down, disconnect all wires from the suspected circuit breaker terminals to prevent interaction.

3.With the generator shut down, connect one meter test lead to a one terminal of the breaker and the other meter test lead to the other terminal. See Figure 6-7.

4.Set the breaker to its ON or “Closed” position. The meter should read CONTINUITY.

5.Set the breaker to its OFF or “Open” position and the meter should indicate INFINITY.

RESULTS:

1.If the circuit breaker tests good, refer back to the flow chart.

2.If the breaker tests bad, it should be replaced.

A B

00.00

ON

50A

 

OFF

C.B.

A B

Figure 6-7. – 50 Amp Breaker Test Points

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Disassembly and Exploded Views 66-71 Magnetism Electromagnetic FieldsElectromagnetic Induction STATORs AC power windings Simple AC GeneratorMore Sophisticated AC Generator Generator Operating Diagram Measuring DC Voltage MetersMeasuring AC Voltage VOMMeasuring Resistance Measuring CurrentOhms Law Electrical UnitsRotor Assembly Introduction AC GeneratorEngine-Generator Drive System Excitation Circuit Breaker Stator AssemblyBrush Holder and Brushes Other AC Generator ComponentsUnderfrequency Adjust 162Voltage Regulator Rotor Residual Magnetism Field Boost CircuitOperation Insulation Resistance MegohmmeterStator Insulation Resistance Test Test Between Windings Testing ALL Stator Windings to GroundCleaning the Generator Rotor Insulation Resistance TestDrying the Generator Circuit Board Connections BatteryRecommended Battery Printed Circuit BoardENGINE DC CONTROL Control Panel Component IdentificationC1 Female Side C1 Male Side C2 Female Side C2 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 If Problem Involves AC Output Problem 1 Voltage & Frequency Are Both High or LowIntroduction Or Replace If BAD Load Watts Problem 5 No 10A Battery Charge Output Problem 4 No Battery Charge OutputProblem 6 Engine Will Not Crank Problem 7 Engine Cranks But Will Not Start Problem 9 Engine Starts Then Shuts Down Problem 8 Engine Starts Hard and Runs RoughProblem 10 10 Amp Fuse F1 Blowing Problem 11 Unit Overspeeds Problem 12 Idle Control RPM Does Not DecreaseProblem 14 Engine Hunts / Erratic Idle Results ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Main Circuit BreakerTest 4 Fixed Excitation Test Rotor AMP Draw If circuit breaker is good, go on to TestSet voltmeter to measure AC voltage Refer to Test 4 Results chart AC Voltage across Wires 11S and 44S=Set a voltmeter to measure resistance Remove air cleaner cover to access stepper motorTest 7 Check Field Boost Test 6 Wire ContinuitySet volt meter to measure resistance Disconnect both wires from the Resistor R1Test 8 DIODE/RESISTOR Set volt meter to the diode test rangeTest 9 Test Stator From the 50 Amp receptacle disconnect WireTest 10 Sensing Leads Unplug the six pin connector at the Voltage RegulatorTest 13 Check Brushes & Slip Rings Test 11 Excitation WiringGain access to the brushes and slip rings Test 12 Check Brush LeadsIf the unit is overloaded, reduce the load Test 14 Check Rotor AssemblyTest 15 Check Load Voltage Frequency Test 16 Check Load Watts & AmperageTest 17 Check Battery Charge Output Test 19 Check Battery Charge Rectifier BCR2Disconnect all wires from the Battery Charge Rectifier Test 22- Check Battery & Cables Test 21- Check 10 Amp FuseBCR1BCR2 Test 25 Check Starter Motor Refer back to flow chartTest 23 Check Voltage at Starter Contactor SC Test 24 Check Starter Contactor SCTools for Starter Performance Test Checking the PinionSet voltmeter to measure DC voltage Test 26 Test Starter Contactor Relay SCRProcedure Set voltmeter to measure resistance Test 27 Check Start-Run-Stop Switch SW1Test 28 Check Start-Run-Stop Switch SW1 Wiring Reconnect all wires to the switchRefer back to the Flow Chart Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 32 Test Start Stop Relay SSR Test 31 Remove Wire 18 / Shutdown LeadRefer to Flow Chart SSR and the Battery Charge Rectifier 2 BCR2RUN Test 33 Test WireTest 34 Test Start Stop Relay Wiring Test 35 Check and Adjust IgnitionMagnetos Magneto Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage Test 38 Check Fuel PumpTest 40 Valve Adjustment Adjusting Valve ClearanceTest 39 Check Carburetion 52 Tightening the Jam Nut Adjust the regulated pressure on the gauge to 80 psiTest 43 Check Start Stop Relay SSR Test 42 Check Oil Pressure Switch WireTest 47 Check Fuel Shutoff Solenoid Test 45 Check Wire 15 CircuitTest 46 Check Wire 14 Circuit Test 44 Test Starter Contactor Relay SCRTest 48 Check Hourmeter Test 50 Check WireTest 49 Check Wire 15B Test 51 Check Wires 11S & 44STB2 Test 52 Check Idle Control SwitchTest 53 Check Idle Control Wiring SW2Test 54 Check Idle Control Transformers ICT Test 55 Check TR1 & TR2 WiringContinuity should be measured Test 56 Choke TestRemove air deflector Figure B, Item #45 from cross member Major DisassemblySupport 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 Rated Max DC Load Amperes Current @ 12 Volts Load %Frequency Hz 238-242 59-61 100 Trim Torque Specifications Torque SpecificationsPO BOX 297 WHITEWATER, WI

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