Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4583, 4582 & 4987, 4451 & 4986, 5308 manual Circuit Condition Rest

Models: 5308 4583 4451 & 4986 4582 & 4987

1 90

Download 90 pages 17.81 Kb

Page 22

Section 4

ENGINE DC CONTROL SYSTEM

					POWER WINDING				DPE WINDING				BA
		BATTERY CHARGE WINDING							DPE WINDING				FIELD
		BATTERY CHARGE WINDING											FIELD
	77A		66A
		55A							2		6	4	0
	C1-5		C1-4	44S	44	22	11	11S	2		6	4	0
	C1-5		C1-4	44S	44	22	11	11S
		C1-3						C1-1	C1-6	C1-7		C1-11	C1-12
								C1-1	C1-6	C1-7		C1-11	C1-12
		10A BATTERY CHARGE WINDING			C1-2	I.C.
		10A BATTERY CHARGE WINDING
	77		66
	77		66		RED
	C1-10		C1-9		RED
	C1-10	55	C1-9	44S				11S	2		6	4	0
		55
						I.C.T.
				66A		I.C.T.
		C1-8		66A
77A		C1-8
77A
					I.C.T.
												11
			66										22
			66		BLK								0
	77				BLK								0
	77				44								44
					44								44
					66A				0
							15
					77A
					BCR1	CB1 BCR2	12Vdc
					66	CB1 BCR2	12Vdc						0
					13A	15A		0
		77			77

			BLK				2
							2
	1	0			0		15
	1	0		CB2	0
				CB2			4		14
	2	162	162			2	4		14
	2	162	162			2	6
							6
ELECTRONIC	3	11S			11S		0	D1	R1
VOLTAGE							0	D1	R1
VOLTAGE
REGULATOR	4	4	4				4		14
	5	44S	44S
	6	6					6
			15				15
			86					86
			0		0
86		15B	229
0			229
15B			167				167
229			83	SW2			0
167				SW2
167							15
83							15
83
									14

TB1	TB2	18
	18	18
	14	14
	15	13

																		15	F1
																	15	15	15
																	15
																			GOVERNOR
												18		14		229			ACTUATOR
												18		14		229
												0	15B					15
		44S			86		167		TR1		15B					14		15
11S				229		TR2		0		83		4	6	5		SSR
12	11	10	9	8	7	6	5	4	3	2	1	12		10	9	SSR
12	11	10	9	8	7	6	5	4	3	2	1

J2						CONTROL							15			13
J2						CONTROL							15
					PRINTED CIRCUIT							0		15		15
J1							BOARD

CIRCUIT CONDITION - REST:

Battery voltage is supplied to components of the control system from the unit BATTERY via the RED battery cable connected to the contacts of the starter contactor (SC), wire 13, a 10 Amp fuse (F1), and Wire 15.

Wire 13 is unfused battery supply voltage and is connected to the contacts of the Starter Contactor Relay (SCR).

Wire 15 12 VDC fused battery supply voltage is supplied to the SCR coil, it goes through the coil and comes out as wire 17 12 VDC, wire 17 is connected to the Start-Run-Stop switch (SW1) and is held open to ground. No cur- rent flows through the circuit and the SCR is de-energized.

Wire 15 12 VDC fused battery supply voltage is supplied to SW1 and is held open to Wire 167.

Wire 15 12 VDC fused battery supply voltage is supplied to the Start-Stop Relay (SSR) it goes through the coil and comes out as wire 229 12 VDC, wire 229 is connected to the printed circuit board and is held open to ground. No current flows through the circuit and the SSR is de-energized.

Page 20

Image 22

Guardian Technologies 4583, 4582 & 4987, 4451 & 4986, 5308 manual Circuit Condition Rest

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 VOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawIntroduction AC Generator Rotor AssemblyEngine-Generator Drive System Other AC Generator Components Stator AssemblyBrush Holder and Brushes 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 Printed Circuit Board BatteryRecommended Battery 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 Test 2 Check Main Circuit Breaker ProcedureTest 1 Check No-Load Voltage Frequency 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 BoostSet volt meter to the diode test range Disconnect both wires from the Resistor R1Test 8 DIODE/RESISTOR 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 12 Check Brush Leads Test 11 Excitation WiringGain access to the brushes and slip rings Test 13 Check Brushes & Slip RingsTest 16 Check Load Watts & Amperage Test 14 Check Rotor AssemblyTest 15 Check Load Voltage Frequency 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 Test 24 Check Starter Contactor SC Refer back to flow chartTest 23 Check Voltage at 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 voltageReconnect all wires to the switch Test 27 Check Start-Run-Stop Switch SW1Test 28 Check Start-Run-Stop Switch SW1 Wiring Procedure Set voltmeter to measure resistanceTest 29 Check Ignition Spark Refer back to the Flow ChartTest 30 Check Spark Plugs SSR and the Battery Charge Rectifier 2 BCR2 Test 31 Remove Wire 18 / Shutdown LeadRefer to Flow Chart Test 32 Test Start Stop Relay SSRTest 33 Test Wire RUNTest 35 Check and Adjust Ignition Test 34 Test Start Stop Relay WiringMagnetos Test 38 Check Fuel Pump Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage 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 44 Test Starter Contactor Relay SCR Test 45 Check Wire 15 CircuitTest 46 Check Wire 14 Circuit Test 47 Check Fuel Shutoff SolenoidTest 51 Check Wires 11S & 44S Test 50 Check WireTest 49 Check Wire 15B Test 48 Check HourmeterSW2 Test 52 Check Idle Control SwitchTest 53 Check Idle Control Wiring 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