Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual = Idle Control Transformer Output

Models: 5308 4583 4451 & 4986 4582 & 4987

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Page 27

Section 4

ENGINE DC CONTROL SYSTEM

120V	120V
DUPLEX	GFCI

11B

11B

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

22

120V/30A

TWISTLOK

22

120V/30A

TWISTLOK

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

00

	C2-7	0
	14	0
	14	14
	C2-5	FSS

8686

LOP0

			0
86	0
	0
	C2-2
	15		15
	C2-10
	15		15
	C2-4		15
	C2-4
	167		167
	C2-3		SW1
15	0	0	17	0
15	C2-8		0
	C2-8

	17		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

	C2-1
18		18
17
	C2-6
13		13
15	C2-11
15
13		13
13
SCR		SC
SCR
	C2-9	16
		16
16
17

D2

IM1

SP1

D3

IM2

SP2

RED

SC

SM

BLACK

BATTERY 12V

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

=IDLE CONTROL TRANSFORMER OUTPUT

The printed circuit board is supplied with AC voltage from Wires 11S and 44S, this voltage /frequency signal is used by the printed circuit board for governor control operation.

When the Idle Control Switch (SW2) is activated to the “ON” position Wire 83 from the printed circuit board will be connected to Wire 0 frame ground. There are two Idle Control Transformers (ICT) that sense current flow off the main power windings. The voltage signal from the ICT’s connect to the Printed Circuit Board via Wires TR1/TR2 and are used for sensing load on the generator. With no-load on the generator there is no current supplied from the ICT’s and the engine will run at a lower RPM. When a load is applied to the generator the ICT’s supply a voltage signal to the Printed Circuit Board and the engine RPM will be increased to running RPM approximately 3600RPM.

Page 25

Image 27

Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual = Idle Control Transformer Output

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