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Guardian Technologies 4582 & 4987, 4451 & 4986, 4583 Electrical Schematic 17.5 kW Drawing No G0733

Models: 5308 4583 4451 & 4986 4582 & 4987

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Section 8

ELECTRICAL DATA

Electrical Schematic 17.5 kW – Drawing No. 0G0733

POWER WINDING

BATTERY CHARGE WINDING
77A			55A		66A	11S	11						22S
C1-5		C1-3		C1-4		C1-1						C1-2	22
10A BATTERY CHARGE WINDING													I.C.
													I.C.
												RED
77			55	66
C1-10		C1-8		C1-9	66A								22S
		C1-8

77				66		11S		I.C.T.					22
77A
										BLK
											11
													66A
													77A
									66
													13A
				77					77
										BCR1
ELECTRONIC				11S		BLK	BLK						22S
ELECTRONIC
	VOLTAGE
	VOLTAGE			22S
REGULATOR				22S
REGULATOR				4									4
				4									4
				0									0
				6									6
				162									162
				86									86
				0									0
				15B
				229
				167									167
				83									83
				BLK
				BLK									15
													15
86	15B	167		11S		229		0			15		15
86	15B	167		11S			15B		15				13
0	229	83		22S			15B		15
0	229	83	TB2	22S					12	10		9
			TB2
													SSR
				22S				4	6		5		SSR
				22S				4	6		5
					11S			18			14		14
0	229	83	TB1	11S					15B				229
			TB1

86	15B	167		22S
													14
													D2
			15B	1						18			IM1
			15B	1								C2-1
			83	2	CONTROL							C2-1
			TR1	3 PRINTED CIRCUIT									D3
			0	4		BOARD							D3
			0	4									IM2
			167	5									IM2
			167	5
			TR2	6

867

2298

	22S	9		GOVERNOR
		10		GOVERNOR
		10	J1	ACTUATOR
	11S	11	J1	ACTUATOR
	11S	11	J2
		12

120V	120V
GFCI	DUPLEX

			DPE WINDING					BA
			DPE WINDING					FIELD
								FIELD
44		2			6	4			0
			C1-6	C1-7			C1-11		C1-12
I.C.T.
		2			6	4			0
								44
								22
								0
								11
					0
15
BCR2
15A
CB1			12Vdc
			12Vdc		0
			15		0	4
			15			4
2
CB2					C2-5
					C2-5		LOP
					86	86
								0
					0
					C2-12
0			0		0	0
SW2								0
								0
4				F1	C2-6
				F1
					13	13		RED
					13	13		RED
D1								SC
								SC
			15		C2-11			BATTERY
					C2-11		SM	12V
R1					13	13	SM	12V
R1					13	13
			SCR		C2-9			BLACK
					C2-9
						16
15		0			16	16	SC
15		0	17
14	167	15	17		C2-8
					C2-8
SP1					17	17
					C2-3		0
					C2-3				0
					0	0		17	0
SP2					C2-4		SW1
					C2-4
					167	167
					C2-10			15
					15	15
					C2-2
					15	15
					C2-7
					14	14		0
							FSS

RESET

TEST

RESET TEST

22	22	22	11B	120/240V	0
			120/240V	120/240V
			120/240V	50A/60A
120V/30A	120V/30A		30A	50A/60A
120V/30A	120V/30A		30A
TWISTLOK	TWISTLOK		TWISTLOK

44C

0

22

11C

0

22

44D

0

11D

0

44B

0

11B

11A

44A

0

22

C.B.

C.B.

C.B.

C.B.

C.B.

C.B.

C.B.

20A

20A

30A

30A

30A

30A

50A/60A

11

11

11

22

22

22

0

0

0

44

44

44

LEGEND

BA - BRUSH ASSEMBLY

FSS - FUEL SHUT OFF SOLENOID

SCR - STARTER CONTACTOR RELAY

BCR1 - BATTERY CHARGE RECTIFIER, 10A

GND - GROUND BAR

SM - STARTER MOTOR

BCR2 - BATTERY CHARGE RECTIFIER

I.C.T. - IDLE CONTROL TRANSFORMER

SP1 - SPARK PLUG, CYL. 1

CB1 - 10AMP AUTO RESET BREAKER

IM1 - IGNITION MODULE, CYL. 1

SP2 - SPARK PLUG, CYL. 2

CB2 - 6AMP AUTO RESET BREAKER

IM2 - IGNITION MODULE, CYL. 2

SSR - START / STOP RELAY

D1 - 600V 12A DIODE

LOP - LOW OIL PRESSURE

SW1 - START-RUN-STOP RELAY

D2, D3 - ENGINE SHUTDOWN DIODE

R1 - 25 OHM, 25W RESISTOR

SW2 - IDLE CONTROL SWITCH

F1 - 10A FUSE

SC - STARTER CONTACTOR

TB1, TB2 - TERMINAL BLOCK

Page 82

Image 84

Guardian Technologies 4582 & 4987, 4451 & 4986, 4583, 5308 manual Electrical Schematic 17.5 kW Drawing No G0733

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 Meters Measuring AC VoltageVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawRotor Assembly Introduction AC GeneratorEngine-Generator Drive System Stator Assembly Brush Holder and BrushesOther AC Generator Components 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 Battery Recommended BatteryPrinted Circuit Board 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 Procedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Main Circuit Breaker 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 BoostDisconnect both wires from the Resistor R1 Test 8 DIODE/RESISTORSet volt meter to the diode test range 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 11 Excitation Wiring Gain access to the brushes and slip ringsTest 12 Check Brush Leads Test 13 Check Brushes & Slip RingsTest 14 Check Rotor Assembly Test 15 Check Load Voltage FrequencyTest 16 Check Load Watts & Amperage 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 Refer back to flow chart Test 23 Check Voltage at Starter Contactor SCTest 24 Check 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 voltageTest 27 Check Start-Run-Stop Switch SW1 Test 28 Check Start-Run-Stop Switch SW1 WiringReconnect all wires to the switch Procedure Set voltmeter to measure resistanceRefer back to the Flow Chart Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 31 Remove Wire 18 / Shutdown Lead Refer to Flow ChartSSR and the Battery Charge Rectifier 2 BCR2 Test 32 Test Start Stop Relay SSRTest 33 Test Wire RUNTest 34 Test Start Stop Relay Wiring Test 35 Check and Adjust IgnitionMagnetos Test 36 Test Fuel Shutoff Solenoid FSS Test 37 Test Fuel Shutoff Solenoid VoltageTest 38 Check Fuel Pump 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 45 Check Wire 15 Circuit Test 46 Check Wire 14 CircuitTest 44 Test Starter Contactor Relay SCR Test 47 Check Fuel Shutoff SolenoidTest 50 Check Wire Test 49 Check Wire 15BTest 51 Check Wires 11S & 44S Test 48 Check HourmeterTest 52 Check Idle Control Switch Test 53 Check Idle Control WiringSW2 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