Guardian Technologies 4451 & 4986, 4582 & 4987, 4583, 5308 Test 26 Test Starter Contactor Relay SCR

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Section 6

DIAGNOSTIC TESTS

Figure 6-32. – Tachometer

Test Bracket:

A starter motor test bracket may be made as shown in Figure 6-33.

 

 

METAL STOCK

 

 

1/4" THICK STEEL

0.5"

2.625"

 

 

 

 

 

3.5"

 

1.0"

4"

 

12"

 

DRILL TWO HOLES — 1/2"

 

FOR STARTER

 

2"

MOUNTING BRACKET

 

 

 

 

 

DRILL TWO HOLES — 1/2"

 

 

FOR MOUNTING TACHOMETER

 

 

TAP FOR 1/4-20 NC SCREWS

Figure 6-33. – Test Bracket Dimensions

Remove Starter Motor:

It is recommended that the Starter Motor be removed from the engine when testing Starter Motor perfor- mance. Assemble starter to test bracket and clamp test bracket in vise (Figure 6-34).

Testing Starter Motor:

1.A fully charged 12 volt battery is required.

2.Connect jumper cables and clamp-on ammeter as shown in Figure 6-34.

3.With the Starter Motor activated (jump the terminal on the Starter Contactor to battery voltage), note the reading on the clamp-on ammeter and on the tachometer (rpm).

 

CLAMP ON

STARTER

AMP METER

 

CONTACTOR

 

STARTER

 

MOTOR

 

TACHOMETER

 

VISE

12 VOLT

BATTERY

Figure 6-34 – Testing Starter Motor Performance

Note: Take the reading after the ammeter and tachometer are stabilized, approximately 2-4 seconds.

4.A starter motor in good condition will be within the following specifications:

Minimum rpm

4500

Maximum Amps

50

Note: Nominal amp draw of starter in generator is 60 amps.

TEST 26 - Test Starter Contactor

Relay (SCR)

PROCEDURE:

1.Set voltmeter to measure DC voltage.

2.Remove Wire 15 from the Starter Contactor Relay (SCR). Connect the positive meter test lead to Wire 15 previous- ly removed. Connect the negative meter test lead to frame Ground. 12 VDC should be measured. Reconnect Wire 15 to the SCR. If 12 VDC is NOT measured on Wire 15 Stop Testing and repair or replace Wire 15 between the Fuse (F1) and the SCR.

3.Remove Wire 13 from the Starter Contactor Relay (SCR). Connect the positive meter test lead to Wire 13 previous- ly removed. Connect the negative meter test lead to frame

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable 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 Measuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Resistance Measuring CurrentOhms Law Electrical UnitsEngine-Generator Drive System Rotor AssemblyIntroduction AC Generator Brush Holder and Brushes Stator AssemblyOther AC Generator Components Excitation Circuit BreakerVoltage Regulator Underfrequency Adjust162 Operation Rotor Residual MagnetismField Boost Circuit Stator Insulation Resistance Test Insulation ResistanceMegohmmeter Test Between Windings Testing ALL Stator Windings to GroundDrying the Generator Cleaning the GeneratorRotor Insulation Resistance Test Recommended Battery BatteryPrinted Circuit Board Circuit Board ConnectionsENGINE DC CONTROL Control Panel Component IdentificationTerminal 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 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 14 Engine Hunts / Erratic Idle Problem 11 Unit OverspeedsProblem 12 Idle Control RPM Does Not Decrease Test 1 Check No-Load Voltage Frequency ProcedureTest 2 Check Main Circuit Breaker ResultsSet voltmeter to measure AC voltage Test 4 Fixed Excitation Test Rotor AMP DrawIf circuit breaker is good, go on to Test 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 ContinuityTest 8 DIODE/RESISTOR Disconnect both wires from the Resistor R1Set volt meter to the diode test range Set volt meter to measure resistanceTest 9 Test Stator From the 50 Amp receptacle disconnect WireTest 10 Sensing Leads Unplug the six pin connector at the Voltage RegulatorGain access to the brushes and slip rings Test 11 Excitation WiringTest 12 Check Brush Leads Test 13 Check Brushes & Slip RingsTest 15 Check Load Voltage Frequency Test 14 Check Rotor AssemblyTest 16 Check Load Watts & Amperage 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 23 Check Voltage at Starter Contactor SC Refer back to flow chartTest 24 Check Starter Contactor SC Test 25 Check Starter MotorTools for Starter Performance Test Checking the PinionSet voltmeter to measure DC voltage Test 26 Test Starter Contactor Relay SCRTest 28 Check Start-Run-Stop Switch SW1 Wiring Test 27 Check Start-Run-Stop Switch SW1Reconnect all wires to the switch Procedure Set voltmeter to measure resistanceTest 30 Check Spark Plugs Refer back to the Flow ChartTest 29 Check Ignition Spark Refer to Flow Chart Test 31 Remove Wire 18 / Shutdown LeadSSR and the Battery Charge Rectifier 2 BCR2 Test 32 Test Start Stop Relay SSRRUN Test 33 Test WireMagnetos Test 34 Test Start Stop Relay WiringTest 35 Check and Adjust Ignition Test 37 Test Fuel Shutoff Solenoid Voltage Test 36 Test Fuel Shutoff Solenoid FSSTest 38 Check Fuel Pump MagnetoTest 39 Check Carburetion Test 40 Valve AdjustmentAdjusting Valve Clearance 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 46 Check Wire 14 Circuit Test 45 Check Wire 15 CircuitTest 44 Test Starter Contactor Relay SCR Test 47 Check Fuel Shutoff SolenoidTest 49 Check Wire 15B Test 50 Check WireTest 51 Check Wires 11S & 44S Test 48 Check HourmeterTest 53 Check Idle Control Wiring Test 52 Check Idle Control SwitchSW2 TB2Test 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 Frequency Hz 238-242 59-61 100 Rated Max DC Load Amperes Current @ 12 VoltsLoad % Trim Torque Specifications Torque SpecificationsPO BOX 297 WHITEWATER, WI

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