Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4582 & 4987, 4451 & 4986, 4583 Test 4 Fixed Excitation Test Rotor AMP Draw

Models: 5308 4583 4451 & 4986 4582 & 4987

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Section 6

DIAGNOSTIC TESTS

00.00	20/30A
	C.B.

TEST 4 - FIXED EXCITATION TEST/

ROTOR AMP DRAW

PROCEDURE:

*NOTE: If the generator is not producing AC Power, loss of governor control may occur caus- ing an overspeed or extremely high RPM condi- tion. If this condition occurs manually control throttle (60Hz /3600 RPM) to perform test.

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

2.Disconnect Wire 14 from the Resistor (R1).

Figure 6-8. – 20/30 Amp Breaker Test Points

TEST 3 - TEST EXCITATION CIRCUIT BREAKER

PROCEDURE:

1.With the generator shut down for at least two minutes, locate the Excitation Circuit Breaker in the control panel. Disconnect wires from the breaker, to prevent interaction.

2.Set a volt meter to measure resistance.

3.Connect the VOM test probes across the circuit breaker termi- nals. The meter should read CONTINUITY.

RESULTS:

1.If circuit breaker tests bad (meter reads “OPEN”) then proceed to Test 4 and replace the breaker after completing Test 4.

2.If circuit breaker is good, go on to Test 4.

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162

2

Figure 6-9. - Testing Excitation Circuit Breaker

3.Connect a jumper wire between the removed end of Wire 14 and Wire 4 where it is soldered at the Diode (D1). See Figure 6-10.

	14
		R1
	14
		D2
	4
	4
	14
	WIRE 14
	REMOVED	R1
	14	R1
	14
	JUMPER LEAD
		D2
	4
	4

Figure 6-10. – Jumper Lead From Wire 14 to Diode

4.Set voltmeter to measure AC voltage

5.Disconnect Wire 2 from the Excitation Circuit Breaker and con- nect one meter test lead to it. Connect the other meter test lead to Wire 6 located in the six pin connector previously removed from the Voltage Regulator. Be careful not to damage the pin connectors with the test leads. See Figure 6-11.

6.Set Idle control switch to OFF.

7.Start the generator.

8.Measure the output voltage across Wire 2 and Wire 6 and record the results.

AC Voltage across Wires 2 and 6 = _____________

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Guardian Technologies 4582 & 4987 Test 4 Fixed Excitation Test Rotor AMP Draw, If circuit breaker is good, go on to Test

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 Meters Measuring AC VoltageVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawIntroduction AC Generator Rotor AssemblyEngine-Generator Drive System Stator Assembly Brush Holder and BrushesOther AC Generator Components 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 Battery Recommended BatteryPrinted Circuit Board 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 Procedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Main Circuit Breaker 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 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 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 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 resistanceTest 29 Check Ignition Spark Refer back to the Flow ChartTest 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 35 Check and Adjust Ignition Test 34 Test Start Stop Relay WiringMagnetos Test 36 Test Fuel Shutoff Solenoid FSS Test 37 Test Fuel Shutoff Solenoid VoltageTest 38 Check Fuel Pump 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 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 Load % Rated Max DC Load Amperes Current @ 12 VoltsFrequency Hz 238-242 59-61 100 Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI