Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual Table of Contents

Page 3

Table of Contents

Safety

Inside Front Cover (IFC)

NOTICE TO USERS OF THIS MANUAL

IFC

REPLACEMENT PARTS

IFC

Table Of Contents

1-2

Section 1:

 

 

Generator Fundamentals

3-5

Magnetism

3

Electromagnetic Fields

3

Electromagnetic Induction

3

A Simple AC Generator

4

A More Sophisticated AC Generator

4

Section 2:

 

 

Measuring Electricity

6-8

Meters

6

The VOM

6

Measuring AC Voltage

6

Measuring DC Voltage

6

Measuring AC Frequency

6

Measuring Current

7

Measuring Resistance

7

Electrical Units

8

Ohm's Law

8

Section 3:

 

 

Description And Components

9-15

Introduction

9

Engine-Generator Drive System

9

The AC Generator

9

Rotor Assembly

9

Stator Assembly

10

Brush Holder and Brushes

10

Other AC Generator Components

10

EXCITATION CIRCUIT BREAKER

10

VOLTAGE REGULATOR

...............................................

11

ADJUSTMENT PROCEDURE

11

Circuit Breakers

12

Rotor Residual Magnetism

12

Field Boost Circuit

12

Operation

12

STARTUP

12

ON-SPEED OPERATION

...............................................

12

FIELD EXCITATION

12

AC POWER WINDING OUTPUT

12

BATTERY CHARGE WINDING OUTPUT

12

10 Amp BATTERY CHARGE WINDING OUTPUT

12

Insulation Resistance

...............................................

13

The Megohmmeter

13

GENERAL

13

TESTING STATOR INSULATION

13

TESTING ROTOR INSULATION

13

HI-POT TESTER

13

Stator Insulation Resistance Test

13

GENERAL

13

TESTING ALL STATOR WINDINGS TO GROUND

14

TEST BETWEEN WINDINGS:

14

Rotor Insulation Resistance Test

15

Cleaning the Generator

15

Drying the Generator

15

Section 4:

 

Engine DC Control System

16-27

Printed Circuit Board

16

GENERAL

16

CIRCUIT BOARD CONNECTIONS

16

Dip switch Positions

16

Battery

16

RECOMMENDED BATTERY

16

Control Panel Component Identification

17-18

Operational Analysis

20-27

CIRCUIT CONDITION - REST

20

CIRCUIT CONDITION - START

22

CIRCUIT CONDITION - RUN

24

CIRCUIT CONDITION - STOP

26

FAULT SHUTDOWN

27

Section 5:

 

Troubleshooting Flowcharts

28-36

Introduction

28

If Problem Involves AC Output

28

Problem 1 -

 

Voltage & Frequency Are Both High or Low ... 28

Problem 2 -

 

Generator Produces Zero Voltage

 

or Residual Voltage (2-12 VAC)

29-30

Problem 3 -

 

Excessive Voltage/Frequency

 

Droop When Load is Applied

30

Problem 4 -

 

No Battery Charge Output

31

Problem 5 -

 

No 10 Amp Battery Charge Output

31

Problem 6 -

 

Engine Will Not Crank

32

Problem 7 -

 

Engine Cranks But Will Not Start

33

Problem 8 -

 

Engine Starts Hard and Runs Rough

34

Problem 9 -

 

Engine Starts Then Shuts Down

34

Problem 10 -

 

10 Amp Fuse (F1) Blowing

35

Problem 11 -

 

Unit Overspeeds

36

Problem 12 -

 

Idle Control “RPM Does Not Decrease”

36

Problem 13 -

 

Idle Control “RPM Does Not Increase

 

When Load Is Applied”

36

Problem 14 -

 

Engine “Hunts” / Erratic Idle

36

 

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable 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 Measuring DC Voltage MetersMeasuring AC Voltage VOMMeasuring Resistance Measuring CurrentOhms Law Electrical UnitsRotor Assembly Introduction AC GeneratorEngine-Generator Drive System Excitation Circuit Breaker Stator AssemblyBrush Holder and Brushes Other AC Generator ComponentsUnderfrequency Adjust 162Voltage Regulator Rotor Residual Magnetism Field Boost CircuitOperation Insulation Resistance MegohmmeterStator Insulation Resistance Test Test Between Windings Testing ALL Stator Windings to GroundCleaning the Generator Rotor Insulation Resistance TestDrying the Generator Circuit Board Connections BatteryRecommended Battery Printed Circuit BoardENGINE DC CONTROL Control Panel Component IdentificationC1 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 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 11 Unit Overspeeds Problem 12 Idle Control RPM Does Not DecreaseProblem 14 Engine Hunts / Erratic Idle Results ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Main Circuit BreakerTest 4 Fixed Excitation Test Rotor AMP Draw If circuit breaker is good, go on to TestSet voltmeter to measure AC voltage 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 ContinuitySet volt meter to measure resistance Disconnect both wires from the Resistor R1Test 8 DIODE/RESISTOR Set volt meter to the diode test rangeTest 9 Test Stator From the 50 Amp receptacle disconnect WireTest 10 Sensing Leads Unplug the six pin connector at the Voltage RegulatorTest 13 Check Brushes & Slip Rings Test 11 Excitation WiringGain access to the brushes and slip rings Test 12 Check Brush LeadsIf the unit is overloaded, reduce the load Test 14 Check Rotor AssemblyTest 15 Check Load Voltage Frequency Test 16 Check Load Watts & AmperageTest 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 Test 25 Check Starter Motor Refer back to flow chartTest 23 Check Voltage at Starter Contactor SC Test 24 Check Starter Contactor SCTools for Starter Performance Test Checking the PinionSet voltmeter to measure DC voltage Test 26 Test Starter Contactor Relay SCRProcedure Set voltmeter to measure resistance Test 27 Check Start-Run-Stop Switch SW1Test 28 Check Start-Run-Stop Switch SW1 Wiring Reconnect all wires to the switchRefer back to the Flow Chart Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 32 Test Start Stop Relay SSR Test 31 Remove Wire 18 / Shutdown LeadRefer to Flow Chart SSR and the Battery Charge Rectifier 2 BCR2RUN Test 33 Test WireTest 34 Test Start Stop Relay Wiring Test 35 Check and Adjust IgnitionMagnetos Magneto Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage Test 38 Check Fuel PumpTest 40 Valve Adjustment Adjusting Valve ClearanceTest 39 Check Carburetion 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 47 Check Fuel Shutoff Solenoid Test 45 Check Wire 15 CircuitTest 46 Check Wire 14 Circuit Test 44 Test Starter Contactor Relay SCRTest 48 Check Hourmeter Test 50 Check WireTest 49 Check Wire 15B Test 51 Check Wires 11S & 44STB2 Test 52 Check Idle Control SwitchTest 53 Check Idle Control Wiring SW2Test 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 Rated Max DC Load Amperes Current @ 12 Volts Load %Frequency Hz 238-242 59-61 100 Trim Torque Specifications Torque SpecificationsPO BOX 297 WHITEWATER, WI

5308, 4583, 4451 & 4986, 4582 & 4987 specifications

Guardian Technologies has carved a niche in the market with its innovative air purification and UV-C sanitization products. The company's model numbers, including 4582, 4987, 4451, 4986, 4583, and 5308, represent a diverse range of solutions designed to enhance indoor air quality and safety in both residential and commercial settings.

The Guardian Technologies 4582 is equipped with a true HEPA filter that captures 99.97% of dust, pollen, smoke, and other particles as small as 0.3 microns. This model features a smart sensor that adjusts the fan speed according to the air quality in real-time. The UV-C light technology integrated into this device works to eliminate viruses and bacteria, providing an additional layer of protection against airborne pathogens.

The 4987 model follows suit with similar advanced features but adds a sleek design ideal for modern interiors. With multiple speed settings and a night mode, the 4987 is perfect for bedrooms or quiet spaces. Its energy-efficient operation coupled with an indicator that signals filter replacement ensures that users maintain optimal performance effortlessly.

The Guardian Technologies 4451 and 4986 models are particularly notable for their enhanced capacity and filtration efficiency. Both units incorporate a three-in-one filtration system that includes a pre-filter, activated charcoal filter, and HEPA filter. With their strategic design, these models not only purify the air but also trap common household odors, making them a popular choice for families with pets.

The 4583 model stands out with a unique combination of design and functionality. It features a low-profile design, making it easy to fit into any space. Its UV-C light technology not only disinfects air but can also sanitize surfaces, bridging the gap between air purification and direct sanitation.

Finally, the Guardian Technologies 5308 caters to larger spaces, offering impressive air circulation and filtration capabilities. Equipped with a high-efficiency particulate air (HEPA) filter and a powerful fan, it effectively cleans larger areas while maintaining whisper-quiet operation.

In summary, Guardian Technologies’ products exemplify a commitment to improving air quality and promoting health through innovative technology. With features like HEPA filtration, UV-C sanitization, smart sensors, and sleek designs, consumers can choose from a range of models that best fit their needs, ensuring cleaner, safer indoor environments.
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