Guardian Technologies 4582 & 4987, 4451 & 4986, 4583, 5308 manual Test 14 Check Rotor Assembly

Page 48

Section 6

DIAGNOSTIC TESTS

BRUSHES

Figure 6-21. – Brush Location

2.Remove Wire 4 from the positive (+) brush terminal.

3.Remove the ground wire (0) from the negative (-) brush.

4.Remove the brush holder, with brushes.

5.Inspect the brushes for excessive wear, damage, cracks, chip- ping, etc.

6.Inspect the brush holder, replace if damaged.

7.Inspect the slip rings.

a.If slip rings appear dull or tarnished they may be cleaned and polished with fine sandpaper. DO NOT USE ANY METALLIC GRIT TO CLEAN SLIP RINGS. (A 400 grit wet sandpaper is rec- ommended).

b.After cleaning slip rings, blow away any sandpa- per residue.

RESULTS:

1.Replace bad brushes. Clean slip rings, if necessary.

2.If brushes and rings are good, go to Test 14.

Test 14 - Check Rotor Assembly

PROCEDURE:

Gain access to the brushes and slip rings. Disconnect Wire 4 and Wire 0 from their respective brushes and remove the brush holder. Then, test the Rotor as fol- lows:

1.Set a voltmeter to measure resistance.

2.Connect the positive (+) meter test lead to the positive (+) slip ring (nearest the Rotor bearing). Connect the common (-) test lead to the negative (-) slip ring. Read the resistance of the Rotor windings, in OHMS.

ROTOR RESISTANCE *

MODEL:

 

 

OHMS

 

 

 

 

004451-0

004986-0

 

7.01Ω

 

 

 

004582-0,1 004987-0

005209-0

7.71Ω

 

 

 

 

004582-2

004987-1

 

13.1Ω

 

 

 

 

004583-0

005308-0

 

14.2Ω

 

 

 

 

*Resistance values in ohms at 20° C. (68° F.). Actual readings may vary depending on ambient temperature. A tolerance of plus or minus 5% is allowed.

3.Connect the positive (+) meter test lead to the positive (+) slip ring, the common (-) test lead to a clean frame ground (such as the Rotor shaft). The meter should read INFINITY.

RESULTS:

1.Replace the Rotor if it fails the test.

2.If Rotor checks good, perform “Rotor Insulation Resistance Test,” on Page 15.

POSITIVE (+)

TEST LEAD

Figure 6-22. – Testing at Slip Rings

Test 15 - Check Load Voltage &

Frequency

PROCEDURE:

Perform this test in the same manner as Test 1, but apply a load to the generator equal to its rated capac- ity. With load applied check voltage and frequency.

Frequency should not drop below about 59 Hertz with the load applied.

Voltage should not drop below about 235 VAC with load applied.

RESULTS:

1.If voltage and/or frequency drop excessively when the load is applied, go to Test 16.

2.If load voltage and frequency are within limits, end tests.

Test 16 - Check Load Watts & Amperage

PROCEDURE:

Add up the wattages or amperages of all loads pow- ered by the generator at one time. If desired, a clamp- on ammeter may be used to measure current flow. See “Measuring Current” on Page 7.

RESULTS:

1. If the unit is overloaded, reduce the load.

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Contents Diagnostic Repair Manual Safety Replacement PartsTable 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 Meters Measuring AC VoltageVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawRotor Assembly Introduction AC GeneratorEngine-Generator Drive System Stator Assembly Brush Holder and BrushesOther AC Generator Components Excitation Circuit BreakerUnderfrequency Adjust 162Voltage Regulator Rotor Residual Magnetism Field Boost CircuitOperation Insulation Resistance MegohmmeterStator Insulation Resistance Test Testing ALL Stator Windings to Ground Test Between WindingsCleaning the Generator Rotor Insulation Resistance TestDrying the Generator Battery Recommended BatteryPrinted Circuit Board Circuit Board ConnectionsControl Panel Component Identification ENGINE DC CONTROLC1 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 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 11 Unit Overspeeds Problem 12 Idle Control RPM Does Not DecreaseProblem 14 Engine Hunts / Erratic Idle Procedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Main Circuit Breaker ResultsTest 4 Fixed Excitation Test Rotor AMP Draw If circuit breaker is good, go on to TestSet 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 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 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 resistanceRefer back to the Flow Chart Test 29 Check Ignition SparkTest 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 34 Test Start Stop Relay Wiring Test 35 Check and Adjust IgnitionMagnetos Test 36 Test Fuel Shutoff Solenoid FSS Test 37 Test Fuel Shutoff Solenoid VoltageTest 38 Check Fuel Pump MagnetoTest 40 Valve Adjustment Adjusting Valve ClearanceTest 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 Rated Max DC Load Amperes Current @ 12 Volts Load %Frequency 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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