Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual QTY Description

Models: 5308 4583 4451 & 4986 4582 & 4987

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Page 71

Section 7

DISASSEMBLY AND EXPLODED VIEWS

ITEM	QTY.	DESCRIPTION

1	1	ADAPTOR, ENGINE

2	1	STATOR

31 ASSEMBLY, ROTOR W/FAN

41 CARRIER, REAR BEARING

51 EXHAUST MANIFOLD

6

1

MUFFLER

71 GASKET, EXHAUST

81 COVER, ALTERNATOR AIR INTAKE

91 BEARING

103 5/16 SPECIAL LOCK WASHER

111 SCREW IHHC 3/8-24 X 15.50 G5

124 SCREW IHHC M8-1.25 X 400 G8.8

131 BRACKET, ALT MOUNTING

144 SCREW HHTT #10-32 X 1.75

151 SCREW HHTT M8-1.2 X 20

161 ENGINE MOUNTING PLATE

176 RUBBER MOUNT

181 BATTERY CABLE, BLACK

191 EARTH STRAP 3/8X 3/8

201 CLIP-J VINYL COAT .625 ID

211 ASSEMBLY, BRUSH HOLDER

221 SCREW TAP-R #10-32 X 9/16

231 WASHER FLAT 3/8 ZINC

ITEM QTY. DESCRIPTION

245 WASHER LOCK 3/8

254 SCREW HHC 3/8-16 X 1-1/4 G5

264 WASHER FLAT 3/8-M10 ZINC

274 SCREW HHC M8-1.25 X 50 G8.8

2821 WASHER FLAT 5/16 ZINC

	29	4	NUT LOCK HEX M8-1.25 NYLON
			INSERT

307 SCREW HHC M6-1.0 X 12

3118 WASHER LOCK M8-5/16

3212 NUT HEX 5/16-18 STEEL

332 SCREW TAPTITE 3/8-16 X 3/4 BP

341 SHIELD, MUFFLER HEAT

351 U-BOLT & SADDLE

364 SCREW SHC M8-1.25 X 18

371 PANEL, MUFFLER BOX BACK

381 PANEL, MUFFLER BOX END

393 SCREW HHTT M6-1.0 X 12

407 WASHER FLAT M6-1/4

417 WASHER LOCK M6-1/4

421 SPARK ARRESTOR SCREEN

431 RETAINER, SPARK ARREST SCREEN

441 SCREW HHTT M4-0.7 X 8

451 SHIELD, RUBBER MOUNT

462 SCREW HHTT M5-0.8 X 16

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Image 71

Guardian Technologies 5308, 4582 & 4987, 4451 & 4986, 4583 manual QTY Description

Contents

Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Disassembly and Exploded Views 66-71 Electromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator STATORs AC power windingsSimple AC Generator Generator Operating Diagram Measuring DC Voltage MetersMeasuring AC Voltage VOMMeasuring Resistance Measuring CurrentOhms Law Electrical UnitsEngine-Generator Drive System Rotor AssemblyIntroduction AC Generator Excitation Circuit Breaker Stator AssemblyBrush Holder and Brushes Other AC Generator ComponentsVoltage Regulator Underfrequency Adjust162 Operation Rotor Residual MagnetismField Boost Circuit Stator Insulation Resistance Test Insulation ResistanceMegohmmeter Test Between Windings Testing ALL Stator Windings to GroundDrying the Generator Cleaning the GeneratorRotor Insulation Resistance Test Circuit Board Connections BatteryRecommended Battery Printed Circuit BoardENGINE DC CONTROL Control Panel Component IdentificationTerminal Block Terminal BLOCKTB2 TB1 C1 Female Side C1 Male SideC2 Female Side C2 Male Side 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 Introduction If Problem Involves AC OutputProblem 1 Voltage & Frequency Are Both High or Low 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 14 Engine Hunts / Erratic Idle Problem 11 Unit OverspeedsProblem 12 Idle Control RPM Does Not Decrease Results ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Main Circuit BreakerSet voltmeter to measure AC voltage Test 4 Fixed Excitation Test Rotor AMP DrawIf circuit breaker is good, go on to Test 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 & AmperageDisconnect all wires from the Battery Charge Rectifier Test 17 Check Battery Charge OutputTest 19 Check Battery Charge Rectifier BCR2 BCR1BCR2 Test 22- Check Battery & CablesTest 21- Check 10 Amp Fuse 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 30 Check Spark Plugs Refer back to the Flow ChartTest 29 Check Ignition Spark 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 WireMagnetos Test 34 Test Start Stop Relay WiringTest 35 Check and Adjust Ignition Magneto Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage Test 38 Check Fuel PumpTest 39 Check Carburetion Test 40 Valve AdjustmentAdjusting Valve Clearance 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 Frequency Hz 238-242 59-61 100 Rated Max DC Load Amperes Current @ 12 VoltsLoad % Trim Torque Specifications Torque SpecificationsPO BOX 297 WHITEWATER, WI