Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual Or Replace If BAD

Models: 5308 4583 4451 & 4986 4582 & 4987

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Page 31

Section 5

TROUBLESHOOTING FLOWCHARTS

Problem 2 - Generator Produces Zero Voltage or Residual Voltage (2-12 VAC)

TEST 2 - CHECK

TEST 3 - TEST

GOOD -PROCEED

GOOD

MAIN CIRCUIT

EXCITATION

BAD -PROCEED, REPLACE AFTER TESTS

BREAKER

CIRCUIT BREAKER

CONCLUDE

RESET

TO

“ON”

OR REPLACE

IF BAD

TEST 4 -

PERFORM FIXED

D

A

EXCITATION /

ROTOR AMP

DRAW

B

C

TEST 12 -

CHECK

BAD

BRUSH

TEST 6 - WIRE

LEADS

CONTINUITY

TEST 9 - TEST

BAD

BAD

STATOR

GOOD

GOOD

GOOD

TEST 7 -

FIELD BOOST

REPAIR

TEST 11 -

TEST 13 -

EXCITATION

BAD

OR

CHECK

WIRING

REPLACE

BRUSHES &

BAD

BAD

REPAIR

SLIP RINGS

GOOD

OR

GOOD

REPLACE,

REPAIR

THEN

GOOD

OR

INSULATION

RETEST

BAD

REPLACE

REPLACE

RESISTANCE

VOLTAGE

TEST PAGE 13

REGULATOR

TEST 14 -

TEST 9 - TEST

BAD

CHECK ROTOR

BAD

STATOR

ASSEMBLY

TEST 8 -

DIODE/RESISTOR

GOOD

BAD

GOOD

REPAIR

TEST 10 -

SENSING

BAD

OR

REPAIR

LEADS

REPLACE

OR

INSULATION

REPLACE,

RESISTANCE

BAD

GOOD

THEN

TEST PAGE 14

RETEST

INSULATION

BAD

RESISTANCE

TEST PAGE 13

Page 29

Image 31

Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual Or Replace If BAD

Contents

Diagnostic Repair Manual Replacement Parts SafetyTable 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 Measuring DC Voltage MetersMeasuring AC Voltage VOMMeasuring Resistance Measuring CurrentOhms Law Electrical UnitsIntroduction AC Generator Rotor AssemblyEngine-Generator Drive System Excitation Circuit Breaker Stator AssemblyBrush Holder and Brushes Other AC Generator Components162 Underfrequency AdjustVoltage Regulator Field Boost Circuit Rotor Residual MagnetismOperation Megohmmeter Insulation ResistanceStator Insulation Resistance Test Test Between Windings Testing ALL Stator Windings to GroundRotor Insulation Resistance Test Cleaning the GeneratorDrying the Generator Circuit Board Connections BatteryRecommended Battery Printed Circuit BoardENGINE DC CONTROL Control Panel Component IdentificationC2 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 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 12 Idle Control RPM Does Not Decrease Problem 11 Unit OverspeedsProblem 14 Engine Hunts / Erratic Idle Results ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Main Circuit BreakerIf circuit breaker is good, go on to Test Test 4 Fixed Excitation Test Rotor AMP DrawSet 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 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 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 29 Check Ignition Spark Refer back to the Flow ChartTest 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 35 Check and Adjust Ignition Test 34 Test Start Stop Relay WiringMagnetos Magneto Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage Test 38 Check Fuel PumpAdjusting Valve Clearance Test 40 Valve AdjustmentTest 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 Load % Rated Max DC Load Amperes Current @ 12 VoltsFrequency Hz 238-242 59-61 100 Trim Torque Specifications Torque SpecificationsPO BOX 297 WHITEWATER, WI