Guardian Technologies 4583, 4582 & 4987, 4451 & 4986, 5308 manual Test 10 Sensing Leads

Page 46

Section 6

DIAGNOSTIC TESTS

12.Connect the meter test leads across Stator lead 2 (Pin 6) at the C1 connector female side and frame ground. Be careful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read.

13.Connect the meter test leads across Stator lead 66 (Pin 9) at the C1 connector female side and frame ground. Be careful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read.

14.Connect the meter test leads across Stator leads Wire 11 and Stator lead 66A (Pin 4) at the C1 connector female side. Be careful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read.

15.Connect the meter test leads across Stator leads Wire 11 and Stator lead 2 (Pin 6) at the C1 connector female side. Be care- ful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read.

16.Connect the meter test leads across Stator leads Wire 11 and Stator lead 66 (Pin 9) at the C1 connector female side. Be care- ful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read.

17.Connect the meter test leads across Stator lead 66A (Pin 4) and Stator lead 2 (Pin 6) at the C1 connector female side. Be careful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read.

18.Connect the meter test leads across Stator lead 66A (Pin 4) and Stator lead 66 (Pin 9) at the C1 connector female side. Be careful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read.

19.Connect the meter test leads across Stator lead 2 (Pin 6) and Stator lead 66 (Pin 9) at the C1 connector female side. Be care- ful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read.

RESULTS:

If the stator fails any step replace it, for Steps 1-10 keep in mind resistance values may vary depending on ambient temperature and calibration of the meter used. If the stator passes all tests refer back to the flow chart.

TEST 10 - SENSING LEADS

PROCEDURE:

1.Set a VOM to measure resistance.

2.Disconnect Connector C1. See Page 17 for connector location.

3.Locate the male side of the connector located on the bottom of the control panel. See Figure 6-19. Connect one meter test lead to Pin 1 Wire 11S. It may be helpful to connect a small jumper lead to the individual pin. Connect the other meter test lead to Wire 11S at Terminal Block 2 (TB2) . See Page 17 for Terminal Block 2 location. Continuity should be measured.

PIN

55

77

 

0

PIN

LOCATION

 

 

 

 

 

 

66

 

 

LOCATION

7

6

4

 

 

12

 

 

 

 

 

 

77A

55A

 

11S PIN

PIN

2

66A

44S

LOCATION

1

LOCATION

 

 

 

 

 

 

 

6

 

 

 

 

Figure 6-19. – C1 Connector, Male Side

4.Locate the male side of the connector located on the bottom of the control panel. See Figure 6-19. Connect one meter test lead to Pin 2 Wire 44S. It may be helpful to connect a small jumper lead to the individual pin. Connect the other meter test lead to Wire 44S at Terminal Block 2 (TB2). Continuity should be measured.

5.Unplug the six pin connector at the Voltage Regulator.

6.Connect the one meter test lead to Wire 11S at Terminal Block 2 (TB2). Connect the other meter test lead to Wire 11S at the six pin connector previously removed from the Voltage Regulator. See Figure 6-11. Be careful not to damage the pin connectors with the test leads. Continuity should be measured.

7.Connect the one meter test lead to Wire 44S at Terminal Block 2 (TB2). Connect the other meter test lead to Wire 44S at the six pin connector previously removed from the Voltage Regulator. See Figure 6-11. Be careful not to damage the pin connectors with the test leads. Continuity should be measured.

RESULTS:

1.If continuity was not measured in any of the steps repair or replace wire.

2.If all steps pass refer back to flow chart.

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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 VOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawIntroduction AC Generator Rotor AssemblyEngine-Generator Drive System Other AC Generator Components Stator AssemblyBrush Holder and Brushes 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 Printed Circuit Board BatteryRecommended Battery 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 Test 2 Check Main Circuit Breaker ProcedureTest 1 Check No-Load Voltage Frequency 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 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 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 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 29 Check Ignition Spark Refer back to the Flow ChartTest 30 Check Spark Plugs 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 RUNTest 35 Check and Adjust Ignition Test 34 Test Start Stop Relay WiringMagnetos Test 38 Check Fuel Pump Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage 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 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 Load % Rated Max DC Load Amperes Current @ 12 VoltsFrequency Hz 238-242 59-61 100 Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI

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