Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4583, 4582 & 4987, 4451 & 4986, 5308 manual Problem 6 Engine Will Not Crank

Models: 5308 4583 4451 & 4986 4582 & 4987

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Page 34

Section 5

TROUBLESHOOTING FLOWCHARTS

Problem 6 - Engine Will Not Crank

TEST 21 -

CHECK 10

AMP FUSE

FUSE BAD

REPLACE FUSE

TEST 22 - CHECK

BATTERY

& CABLES

RECHARGE OR REPLACE BATTERY

BAD - CLEAN, REPAIR OR REPLACE BAD

CABLE(S)

FUSE BLOWS GO TO PROBLEM 9

GOOD

TEST 23 - CHECK

VOLTAGE AT

STARTER

CONTACTOR

12VDC

MEASURED

TEST 24 - CHECK

STARTER

CONTACTOR

GOOD

NO VOLTAGE

MEASURED

BAD REPLACE

TEST 26 - CHECK

STARTER

CONTACTOR

RELAY (SCR)

BAD

REPAIR OR

REPLACE WIRING

OR SCR

			TEST 27 - CHECK
GOOD			TEST 27 - CHECK
			START-RUN-STOP
			START-RUN-STOP
			SWITCH (SW1)


				GOOD



			TEST 28 - CHECK
			START-RUN-STOP
			SWITCH (SW1)
			WIRING

				GOOD

			REPAIR OR
			REPLACE WIRE 16

BAD REPLACE

REPAIR

BAD WIRING

TEST 25 - CHECK STARTER MOTOR

GOOD

	BAD	REPLACE STARTER
	BAD	MOTOR IF DEFECTIVE
		MOTOR IF DEFECTIVE

CHECK FOR

MECHANICAL BINDING

OF THE ENGINE OR

ROTOR

Page 32

Image 34

Guardian Technologies 4583, 4582 & 4987, 4451 & 4986, 5308 manual Problem 6 Engine Will Not Crank

Contents

Diagnostic Repair Manual Safety Replacement PartsTable 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 VOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawIntroduction AC Generator Rotor AssemblyEngine-Generator Drive System Other AC Generator Components Stator AssemblyBrush Holder and Brushes Excitation Circuit Breaker162 Underfrequency AdjustVoltage Regulator Field Boost Circuit Rotor Residual MagnetismOperation Megohmmeter Insulation ResistanceStator Insulation Resistance Test Testing ALL Stator Windings to Ground Test Between WindingsRotor Insulation Resistance Test Cleaning the GeneratorDrying the Generator Printed Circuit Board BatteryRecommended Battery Circuit Board ConnectionsControl Panel Component Identification ENGINE DC CONTROLC2 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 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 12 Idle Control RPM Does Not Decrease Problem 11 Unit OverspeedsProblem 14 Engine Hunts / Erratic Idle Test 2 Check Main Circuit Breaker ProcedureTest 1 Check No-Load Voltage Frequency ResultsIf circuit breaker is good, go on to Test Test 4 Fixed Excitation Test Rotor AMP DrawSet 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 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 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 resistanceTest 29 Check Ignition Spark Refer back to the Flow ChartTest 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 35 Check and Adjust Ignition Test 34 Test Start Stop Relay WiringMagnetos Test 38 Check Fuel Pump Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage MagnetoAdjusting Valve Clearance Test 40 Valve AdjustmentTest 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 Load % Rated Max DC Load Amperes Current @ 12 VoltsFrequency Hz 238-242 59-61 100 Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI