Guardian Technologies 4451 & 4986, 4583 Test 52 Check Idle Control Switch, TB2, SW2 Offon

Page 65

Section 6

DIAGNOSTIC TESTS

Connect one meter test lead to pin location J2-10 Wire 44S of the connector just removed. Be careful not to damage the pin connectors with the test leads. Connect the other meter test lead to Wire 44S at Terminal Block 2 (TB2). CONTINUITY should be measured.

3.Connect one meter test lead to pin location J2-12 Wire 11S. Be careful not to damage the pin connectors with the test leads. Connect the other meter test lead to Wire 11S at Terminal Block 2 (TB2). CONTINUITY should be measured.

 

44S 11S

 

 

 

00.00

 

TB2

 

 

STEP 2

 

 

STEP 3

 

 

STEP 2

STEP 3

J2-1

J2-12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAKE SURE THE TEST

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBE CONNECTOR IS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAKING CONTACT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WITH THE CONNECTOR.

J2 HARNESS CONNECTOR

DOUBLE CHECK TO

MAKE SURE THAT THE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TIP IS SHARP.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 6-58. – Check Wires 11S & 44S

RESULTS:

1.If CONTINUITY was not measured, repair or replace the wire harness.

2.If CONTINUITY was measured, refer back to the flow chart.

TEST 52 - CHECK IDLE CONTROL SWITCH

(SW2)

PROCEDURE:

1.Set a voltmeter to measure resistance.

2.Disconnect Wire 0 and Wire 83 from the Idle Control Switch (SW2).

3.Connect meter test leads across both terminals of SW2. See Figure 6-59.

4.In the OFF position the meter should read INFINITY or Open. In the ON position the meter should read CONTINUITY or Closed.

RESULTS:

1.If the switch fails Step 4 replace it.

2.If the switch is good refer back to the flow chart.

SW2

OFFON

OL

00.00

Figure 6-59. – Check Idle Control Switch (SW2)

TEST 53 - CHECK IDLE CONTROL WIRING

PROCEDURE:

1.Set a voltmeter to measure resistance.

2.Disconnect Wire 0 from the Idle Control Switch (SW2).

3.Connect one meter test lead to Wire 0. Connect the other meter test lead to frame ground. CONTINUITY should be measured. If continuity is not measured repair or replace Wire 0 between SW2 and the ground terminal.

4.Disconnect Wire 83 from SW2. Disconnect the J2 connector from the printed circuit board.

5.Connect one meter test lead to Wire 83 previously removed from SW2. Connect the other meter test lead to pin location J2-2 on the J2 connector. See Figure 6-60. Be careful not to damage the pin connectors with the test leads. CONTINUITY should be measured. If CONTINUITY is not measured repair or replace Wire 83 between the J2 connector and Terminal Block or between the Terminal Block and SW2.

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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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