Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4583, 4582 & 4987, 4451 & 4986 Introduction, If Problem Involves AC Output

Models: 5308 4583 4451 & 4986 4582 & 4987

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Section 5

TROUBLESHOOTING FLOWCHARTS

Introduction

The “Flow Charts” in this section may be used in conjunction with the “Diagnostic Tests” of Section 6. Numbered tests in the Flow Charts correspond to identically numbered tests of Section 6.

Problems 1 through 5 apply to the AC generator only.

Beginning with Problem 5, the engine DC control sys- tem is dealt with.

If Problem Involves AC Output

TEST 1 - CHECK NO

LOAD VOLTAGE &

FREQUENCY

NO-LOAD VOLTAGE &

FREQUENCY GOOD -

VOLTAGE &

FREQUENCY GOOD -

FREQUENCY GOOD -

ZERO VOLTAGE AND

VOLTAGE HIGH

FREQUENCY BOTH

ZERO OR RESIDUAL

OR

ZERO FREQUENCY

HIGH OR LOW

VOLTAGE

VOLTAGE/FREQUENCY

VOLTAGE LOW

FALLS OFF UNDER LOAD

GO TO PROBLEM 1

GO TO VOLTAGE

GO TO PROBLEM 2

GO TO PROBLEM 2

GO TO PROBLEM 3

(BELOW)

REGULATOR

ADJUSTMENT,

PAGE 11

Problem 1 - Voltage & Frequency Are Both High or Low

TEST 5 - CHECK STEPPER MOTOR CONTROL

FREQUENCY IS GOOD,

BUT NO-LOAD

VOLTAGE IS HIGH

OR VOLTAGE

IS LOW

GO TO VOLTAGE

REGULATOR

ADJUSTMENT,

PAGE 11

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Guardian Technologies 4583 Introduction, If Problem Involves AC Output, Problem 1 Voltage & Frequency Are Both High or Low

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 VOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawRotor Assembly Introduction AC GeneratorEngine-Generator Drive System Other AC Generator Components Stator AssemblyBrush Holder and Brushes 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 Printed Circuit Board BatteryRecommended Battery 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 Test 2 Check Main Circuit Breaker ProcedureTest 1 Check No-Load Voltage Frequency 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 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 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 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 resistanceRefer back to the Flow Chart Test 29 Check Ignition SparkTest 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 34 Test Start Stop Relay Wiring Test 35 Check and Adjust IgnitionMagnetos Test 38 Check Fuel Pump Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage 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 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 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