Guardian Technologies 4390, 4456, 4389, 4760, 4759, 4758 Test 77 Test Exercise Function, Continuity

SECTION 4.4

DIAGNOSTIC TESTS

PART 4

DC CONTROL

J1-4, Wire 194	If	CONTINUITY	was
	measured, go to Step 4.
	Average nominal resistance
	reading: 110-120 ohms.
J1-5, Wire 56	If	CONTINUITY	was
	measured, go to Step 5.
	Average nominal resistance
	reading V-twin (SCR): 150-
	160 ohms, Single Cylinder
	(SC): 4 ohms.
J1-10, Wire 15A	If	CONTINUITY	was
	measured, repair or replace
	shorted to ground Wire 15A
	between Connector J1 and
	switch SW1.
J1-7, Wire 14	If	CONTINUITY	was
	measured, go to Step 6.

4.Disconnect Wire 194 from the terminal strip. Repeat Step 3 at Pin Location J1-4.

a.If CONTINUITY was measured, Wire 194 is shorted to ground between Connector J1 and terminal strip.

b.If INFINITY was measured, disconnect Wire 194 from the transfer switch terminal strip. Connect one meter test lead to the end of Wire 194 which was removed from the transfer switch terminal strip. Connect the other meter test lead to the ground terminal. If CONTINUITY was measured, Wire 194 is shorted to ground between the generator and the transfer switch.

1)If INFINITY was measured, disconnect Wire 194 from the transfer relay (TR). Connect one meter test lead to the transfer relay terminal from which Wire 194 was previously removed. Connect the other test lead to Wire 23 at the transfer switch terminal strip. If CONTINUITY ZERO RESISTANCE was measured, replace the transfer relay. Normal coil resistance is approximately 113 ohms.

2)If coil resistance of 113 ohms was measured, the short is in Wire 194 between the transfer relay and the terminal strip. Repair or replace Wire 194.

5.Disconnect Wire 56 From the starter contactor relay (SCR on V-twin) or the starter contactor (SC on single cylinder). Connect one meter test lead to the SCR or SC terminal from which Wire 56 was removed. Connect the

other meter test lead to the ground terminal. If CONTINUITY or zero resistance was measured, replace the SCR or SC. Coil resistance for the SCR is 155 ohms. Coil resistance for the SC is 4 ohms. If coil resistance was measured, Wire 56 is shorted to ground between Connector J1 and the SCR or SC. Repair or replace the shorted wire.

6.Disconnect and isolate each Wire 14 from the 4-tab insulated terminal block. Repeat Step 3 for Pin Location J1-7. If CONTINUITY was measured, repair or replace Wire 14 between Connector J1 and the 4-tab terminal block. If INFINITY was measured, proceed as follows:

a.Disconnect Wire 14 from the following: fuel solenoid (FS), battery charge relay (BCR) and hourmeter (HM) if equipped.

b.Connect the negative (-) meter test lead to the ground terminal. Connect the positive (+) meter test lead to each of the listed components at the terminal from which Wire 14 was removed. If CONTINUITY or zero resistance was measured, the component has shorted to ground. Replace the component. The average nominal resistance value that should be measured for each component is:

Battery Charge Relay (BCR) - 112 ohms Fuel Solenoid (FS) - 31 ohms Hourmeter (HM) - 2 Mega ohms to infinity

c.If each component tests good, there is no short to ground. The fault exists in one of the Wire 14 wires. Connect one meter test lead to the ground terminal. Connect the other meter test lead to each Wire 14 individually (on the end removed from the BCR, FS or HM). The Wire 14 which measures CONTINUITY is shorted to ground. Repair or replace the affected wire between the component and the 4-tab terminal block.

TEST 77 - TEST EXERCISE FUNCTION

DISCUSSION:

The following parameters must be met in order for the weekly exercise to occur:

❏AUTO-OFF-MANUAL switch (SW1) set to AUTO.

❏Circuit board DIP Switch 2 (REMOTE NOT AUTO) set to OFF.

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