Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

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

Models: 5308 4583 4451 & 4986 4582 & 4987

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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						167			167
	15B																	167			167
		229																83		0
			167															SW2
			167																		15
				83																	15
				83
																						14
							TB1					TB2						18				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 - START:

With the Start-Run-Stop Switch (SW1) held in the start position, Wire 17 from the Starter Contactor Relay (SCR) is now connected to Wire 0 which is frame ground. This allows current to flow and the SCR is energized. The SCR contacts close connecting Wire 13 battery power to Wire 16. Wire 16 now supplies battery power to the starter contactor (SC) on the Starter Motor (SM), the SC is energized and its contacts close, battery power is available to the Starter Motor (SM) and the engine is cranking.

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

Contents

Diagnostic Repair Manual Safety Replacement PartsTable 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 Meters Measuring AC VoltageVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawRotor Assembly Introduction AC GeneratorEngine-Generator Drive System Stator Assembly Brush Holder and BrushesOther AC Generator Components Excitation Circuit BreakerUnderfrequency Adjust 162Voltage Regulator Rotor Residual Magnetism Field Boost CircuitOperation Insulation Resistance MegohmmeterStator Insulation Resistance Test Testing ALL Stator Windings to Ground Test Between WindingsCleaning the Generator Rotor Insulation Resistance TestDrying the Generator Battery Recommended BatteryPrinted Circuit Board Circuit Board ConnectionsControl Panel Component Identification ENGINE DC CONTROLC1 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 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 11 Unit Overspeeds Problem 12 Idle Control RPM Does Not DecreaseProblem 14 Engine Hunts / Erratic Idle Procedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Main Circuit Breaker ResultsTest 4 Fixed Excitation Test Rotor AMP Draw If circuit breaker is good, go on to TestSet 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 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 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 resistanceRefer back to the Flow Chart Test 29 Check Ignition SparkTest 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 34 Test Start Stop Relay Wiring Test 35 Check and Adjust IgnitionMagnetos Test 36 Test Fuel Shutoff Solenoid FSS Test 37 Test Fuel Shutoff Solenoid VoltageTest 38 Check Fuel Pump MagnetoTest 40 Valve Adjustment Adjusting Valve ClearanceTest 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 Rated Max DC Load Amperes Current @ 12 Volts Load %Frequency Hz 238-242 59-61 100 Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI