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Portable Generator
Guardian Technologies
4451 & 4986, 4582 & 4987, 4583, 5308 manual
Models:
5308
4583
4451 & 4986
4582 & 4987
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Specification
Generator Operating Diagram
Replacement Parts
Test 6 Wire Continuity
If Problem Involves AC Output
Diagnostic Repair Manual
Rotor Assembly
Procedure
Fault Shutdown
Underfrequency Adjust
Page 21
Image 21
NOTES
Page 19
Page 20
Page 22
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Page 20
Page 22
Contents
Diagnostic Repair Manual
Replacement Parts
Safety
Table of Contents
Section Disassembly and Exploded Views 66-71
Magnetism
Electromagnetic Fields
Electromagnetic Induction
STATORs AC power windings
Simple AC Generator
More Sophisticated AC Generator
Generator Operating Diagram
Measuring AC Voltage
Meters
VOM
Measuring DC Voltage
Measuring Resistance
Measuring Current
Ohms Law
Electrical Units
Rotor Assembly
Introduction AC Generator
Engine-Generator Drive System
Brush Holder and Brushes
Stator Assembly
Other AC Generator Components
Excitation Circuit Breaker
Underfrequency Adjust
162
Voltage Regulator
Rotor Residual Magnetism
Field Boost Circuit
Operation
Insulation Resistance
Megohmmeter
Stator Insulation Resistance Test
Test Between Windings
Testing ALL Stator Windings to Ground
Cleaning the Generator
Rotor Insulation Resistance Test
Drying the Generator
Recommended Battery
Battery
Printed Circuit Board
Circuit Board Connections
ENGINE DC CONTROL
Control Panel Component Identification
C1 Female Side C1 Male Side
C2 Female Side C2 Male Side
Terminal 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 Low
Introduction
Or Replace If BAD
Load Watts
Problem 5 No 10A Battery Charge Output
Problem 4 No Battery Charge Output
Problem 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 Rough
Problem 10 10 Amp Fuse F1 Blowing
Problem 11 Unit Overspeeds
Problem 12 Idle Control RPM Does Not Decrease
Problem 14 Engine Hunts / Erratic Idle
Test 1 Check No-Load Voltage Frequency
Procedure
Test 2 Check Main Circuit Breaker
Results
Test 4 Fixed Excitation Test Rotor AMP Draw
If circuit breaker is good, go on to Test
Set 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 motor
Test 7 Check Field Boost
Test 6 Wire Continuity
Test 8 DIODE/RESISTOR
Disconnect both wires from the Resistor R1
Set volt meter to the diode test range
Set volt meter to measure resistance
Test 9 Test Stator
From the 50 Amp receptacle disconnect Wire
Test 10 Sensing Leads
Unplug the six pin connector at the Voltage Regulator
Gain access to the brushes and slip rings
Test 11 Excitation Wiring
Test 12 Check Brush Leads
Test 13 Check Brushes & Slip Rings
Test 15 Check Load Voltage Frequency
Test 14 Check Rotor Assembly
Test 16 Check Load Watts & Amperage
If the unit is overloaded, reduce the load
Test 17 Check Battery Charge Output
Test 19 Check Battery Charge Rectifier BCR2
Disconnect all wires from the Battery Charge Rectifier
Test 22- Check Battery & Cables
Test 21- Check 10 Amp Fuse
BCR1BCR2
Test 23 Check Voltage at Starter Contactor SC
Refer back to flow chart
Test 24 Check Starter Contactor SC
Test 25 Check Starter Motor
Tools for Starter Performance Test
Checking the Pinion
Set voltmeter to measure DC voltage
Test 26 Test Starter Contactor Relay SCR
Test 28 Check Start-Run-Stop Switch SW1 Wiring
Test 27 Check Start-Run-Stop Switch SW1
Reconnect all wires to the switch
Procedure Set voltmeter to measure resistance
Refer back to the Flow Chart
Test 29 Check Ignition Spark
Test 30 Check Spark Plugs
Refer to Flow Chart
Test 31 Remove Wire 18 / Shutdown Lead
SSR and the Battery Charge Rectifier 2 BCR2
Test 32 Test Start Stop Relay SSR
RUN
Test 33 Test Wire
Test 34 Test Start Stop Relay Wiring
Test 35 Check and Adjust Ignition
Magnetos
Test 37 Test Fuel Shutoff Solenoid Voltage
Test 36 Test Fuel Shutoff Solenoid FSS
Test 38 Check Fuel Pump
Magneto
Test 40 Valve Adjustment
Adjusting Valve Clearance
Test 39 Check Carburetion
52 Tightening the Jam Nut
Adjust the regulated pressure on the gauge to 80 psi
Test 43 Check Start Stop Relay SSR
Test 42 Check Oil Pressure Switch Wire
Test 46 Check Wire 14 Circuit
Test 45 Check Wire 15 Circuit
Test 44 Test Starter Contactor Relay SCR
Test 47 Check Fuel Shutoff Solenoid
Test 49 Check Wire 15B
Test 50 Check Wire
Test 51 Check Wires 11S & 44S
Test 48 Check Hourmeter
Test 53 Check Idle Control Wiring
Test 52 Check Idle Control Switch
SW2
TB2
Test 54 Check Idle Control Transformers ICT
Test 55 Check TR1 & TR2 Wiring
Continuity should be measured
Test 56 Choke Test
Remove air deflector Figure B, Item #45 from cross member
Major Disassembly
Support 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 Specifications
PO BOX 297 WHITEWATER, WI