Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual = 12 VDC Control

Models: 5308 4583 4451 & 4986 4582 & 4987

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Page 23

Section 4

ENGINE DC CONTROL SYSTEM

11B

	11B
0	120/240V	22	22	22
120/240V	120/240V
50A	30A		120V/30A	120V/30A
	TWISTLOK		TWISTLOK	TWISTLOK

120V	120V
DUPLEX	GFCI
TEST	RESET
TEST	RESET

0	44A	11A	0	44B	0	11D	0	44D	22	0	11C	22	0	44C
C.B.		22		C.B.		C.B.		C.B.			C.B.			C.B.
C.B.				C.B.		C.B.		C.B.			C.B.			C.B.
30A		C.B.		30A		30A		30A			20A			20A
		C.B.
	11	50A				11					11
	11					11					11
	22					22					22
	0					0					0
	44					44					44

	C2-12
	0	0
	C2-7		0
	14	14	0
	14	14
	C2-5		FSS
	86	86
		LOP	0
			0

86 0

	C2-2
15				15
	C2-10
15				15
	C2-4			15
	C2-4
167				167
	C2-3			SW1
0			0	17	0
15	C2-8			0
	C2-8

17				17
	C2-1		D2
18		18		IM1
				SP1
			D3
17				IM2
17				SP2
				SP2
	C2-6
13		13		RED
15	C2-11			SC
13		13
13
SCR		SC		SM
SCR
	C2-9	16			BATTERY
	C2-9				12V

16				BLACK
16				BLACK
17

LEGEND

BA - BRUSH ASSEMBLY

BCR1 - BATTERY CHARGE RECTIFIER, 10A BCR2 - BATTERY CHARGE RECTIFIER CB1 - 10AMP AUTO RESET BREAKER CB2 - 5AMP AUTO RESET BREAKER

D1 - 600V 12A DIODE

D2, D3 - ENGINE SHUTDOWN DIODE F1 - 10A FUSE

FSS - FUEL SHUT OFF SOLENOID GND - GROUND BAR

I.C.T. - IDLE CONTROL TRANSFORMER IM1 - IGNITION MODULE, CYL. 1

IM2 - IGNITION MODULE, CYL. 2

LOP - LOW OIL PRESSURE

R1 - 25 OHM, 25W RESISTOR

SC - STARTER CONTACTOR

SCR - STARTER CONTACTOR RELAY SM - STARTER MOTOR

SP1 - SPARK PLUG, CYL. 1

SP2 - SPARK PLUG, CYL. 2

SSR - START / STOP RELAY SW1 - START-RUN-STOP SWITCH SW2 - IDLE CONTROL SWITCH TB1, TB2 - TERMINAL BLOCK

=12 VDC SUPPLY

=12 VDC CONTROL

=AC POWER

=GROUND

Wire 15 12 VDC fused battery supply voltage is supplied to the normally open contacts of the SSR. One set of normally open contacts are connected to Wire 15B, the other set of normally open contacts are connected to Wire 14. The SSR is de-energized and no voltage is available through the contacts.

Wire 15 12 VDC fused battery supply voltage is supplied to the Battery Charge Rectifier number 2 (BCR2). This is a return current path for battery charging. No current flows at this time.

Wire 18 connects to the ignition magnetos and to the normally closed contacts of the SSR. The normally closed contacts are also connected to Wire 0, Wire 0 is frame ground.

The SSR is de-energized and the magnetos are grounded out at this time, no spark is available.

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Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual = 12 VDC Control

Contents

Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Disassembly and Exploded Views 66-71 Electromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator STATORs AC power windingsSimple AC Generator Generator Operating Diagram Measuring DC Voltage MetersMeasuring AC Voltage VOMMeasuring Resistance Measuring CurrentOhms Law Electrical UnitsEngine-Generator Drive System Rotor AssemblyIntroduction AC Generator Excitation Circuit Breaker Stator AssemblyBrush Holder and Brushes Other AC Generator ComponentsVoltage Regulator Underfrequency Adjust162 Operation Rotor Residual MagnetismField Boost Circuit Stator Insulation Resistance Test Insulation ResistanceMegohmmeter Test Between Windings Testing ALL Stator Windings to GroundDrying the Generator Cleaning the GeneratorRotor Insulation Resistance Test Circuit Board Connections BatteryRecommended Battery Printed Circuit BoardENGINE DC CONTROL Control Panel Component IdentificationTerminal Block Terminal BLOCKTB2 TB1 C1 Female Side C1 Male SideC2 Female Side C2 Male Side 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 Introduction If Problem Involves AC OutputProblem 1 Voltage & Frequency Are Both High or Low 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 14 Engine Hunts / Erratic Idle Problem 11 Unit OverspeedsProblem 12 Idle Control RPM Does Not Decrease Results ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Main Circuit BreakerSet voltmeter to measure AC voltage Test 4 Fixed Excitation Test Rotor AMP DrawIf circuit breaker is good, go on to Test 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 & AmperageDisconnect all wires from the Battery Charge Rectifier Test 17 Check Battery Charge OutputTest 19 Check Battery Charge Rectifier BCR2 BCR1BCR2 Test 22- Check Battery & CablesTest 21- Check 10 Amp Fuse 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 switchTest 30 Check Spark Plugs Refer back to the Flow ChartTest 29 Check Ignition Spark 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 WireMagnetos Test 34 Test Start Stop Relay WiringTest 35 Check and Adjust Ignition Magneto Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage Test 38 Check Fuel PumpTest 39 Check Carburetion Test 40 Valve AdjustmentAdjusting Valve Clearance 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 Frequency Hz 238-242 59-61 100 Rated Max DC Load Amperes Current @ 12 VoltsLoad % Trim Torque Specifications Torque SpecificationsPO BOX 297 WHITEWATER, WI