Guardian 4451 & 4986 manual

www .guardiangenerators.com POR T ABLES PO BO X 297 • WHITEW A TER, WI 53190 www .guardiangenerators .com P/N OF7713 REV . A Printed in the USA 6.06 MODELS: 4451 & 4986 (12,500 Watt) 4582 & 4987 (15,000 Watt) 4583 (17,500 Watt) 5209 (15,000 Watt) 5308 (17,500 Watt) UL TRA SOURCE POR T ABLE GENERA TOR DIAGNOSTIC REP AIR MANUAL 0F7713 Cover[...]

SAFETY Throughout this publication, "D ANGER!" and "CA UTION!" blocks are used to alert the mechanic to special instructions concerning a par ticular ser vice or operation that might be hazardous if performed incorrectly or carelessly . P A Y CLOSE A TTENTION T O THEM. * D ANGER! UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCT[...]

T able of Contents P age 1 SAFETY .................. INSIDE FRONT CO VER (IFC) NOTICE TO USERS OF THIS MANUAL ..............................IFC REPLACEMENT P ARTS ..................................................... IFC T ABLE OF CONTENTS ...................................... 1-2 SECTION 1: GENERA T OR FUNDAMENT ALS ....................... 3-5 MA[...]

T able of Contents P age 2 SECTION 6: DIA GNOSTIC TESTS ...................................... 37-65 INTRODUCTION .............................................................. 37 TEST 1 - CHECK NO-LOAD VOL T AGE AND FREQUENCY .. 37 TEST 2 - CHECK MAIN CIRCUIT BREAKER ........................ 37 TEST 3- TEST EXCIT A TION CIRCUIT BREAKER ...........[...]

Section 1 GENERA T OR FUND AMENT ALS MA GNETISM Magnetism can be used to produce electricity and electricity can be used to produce magnetism. Much about magnetism cannot be e xplained by our present knowledge . How ev er , there are cer tain pat - terns of beha vior that are known. Application of these behavior patter ns has led to the dev elopmen[...]

Section 1 GENERA T OR FUND AMENT ALS A SIMPLE A C GENERA T OR Figure 1-4 shows a very simple AC Generator . The generator consists of a rotating magnetic field called a RO T OR and a stationar y coil of wire called a ST A T OR. The RO T OR is a per manent magnet which consists of a SOUTH magnetic pole and a NORTH magnetic pole. As the MO T OR tur n[...]

Section 1 GENERA T OR FUND AMENT ALS 2. During star tup, pr inted circuit board action controls the ST AR T/ ST OP RELA Y to deliver batter y voltage to the RO T OR, via the brushes and slip rings. a. The batter y voltage is called “Field Boost”. b . Flow of direct current through the RO TOR increases the strength of the magnetic field abov e t[...]

Section 2 MEASURING ELECTRICITY METERS De vices used to measure electr ical proper ties are called meters. Meters are av ailable that allow one to measure (a) A C voltage , (b) DC voltage, (c) A C frequency , and (d) resistance in ohms. The following apply: • T o measure A C voltage, use an A C voltmeter . • T o measure DC voltage , use a DC vo[...]

Section 2 MEASURING ELECTRICITY engine speed gov er nor . For models rated 60 Her tz, the gov er nor is generally set to maintain a no-load fre- quency of about 62 Her tz with a corresponding output v oltage of about 124 volts AC line-to-neutral. Engine speed and frequency at no-load are set slightly high to prev ent excessiv e rpm and frequency dr[...]

Section 2 MEASURING ELECTRICITY Component testing ma y require a specific resis- tance value or a test f or INFINITY or CONTINUITY . Infinity is an OPEN condition between two electrical points, which would read as no resistance on a V OM. Continuity is a CLOSED condition between two elec- trical points, which would be indicated as very low resistan[...]

Section 3 DESCRIPTION & COMPONENTS INTRODUCTION The generator rev olving field (rotor) is driven by an air-cooled engine at about 3600 r pm. The generator ma y be used to supply electrical power f or the operation of 120 and/or 240 volts, 1-phase, 60 Hz, A C loads. ENGINE-GENERA T OR DRIVE SYSTEM The generator rev olving field is driven by an a[...]

Section 3 DESCRIPTION & COMPONENTS Figure 3-2. – The 2-P ole Rotor Assembly ST A T OR ASSEMBL Y The stator can houses and retains (a) dual A C power windings, (b) an excitation winding, and (c) two bat- ter y charge windings. A total of thir teen (13) stator leads are brought out of the stator can as shown in Figure 3-3. The stator can is san[...]

Section 3 DESCRIPTION & COMPONENTS 2 162 Figure 3-5. – Excitation Circuit Breaker V OL T AGE REGULA TOR: A typical V oltage Regulator is shown in Figure 3-6 (12.5 & 15 kW Units) or Figure 3-7 (17.5 kW Units). Unregulated A C output from the stator excitation winding is deliv ered to the regulator’ s DPE ter mi- nals, via Wire 2, the Exc[...]

Section 3 DESCRIPTION & COMPONENTS with a 62 Hz AC frequency (62 Hz equals 3720 rpm). At the stated no-load frequency , adjust to obtain a line-to-line A C voltage of about 252 v olts. CIRCUIT BREAKERS: Each individual outlet on the generator is protected by a circuit breaker to pre vent ov erload. RO T OR RESIDU AL MA GNETISM The generator rev[...]

Section 3 DESCRIPTION & COMPONENTS The resulting direct current from the BCR is delivered to the 12 VDC receptacle, via Wire 13A, CB1, and Wire 15A. This receptacle allows the capability to recharge a 12 volt DC storage batter y with provided batter y charge cables . INSULA TION RESIST ANCE The insulation resistance of stator and rotor wind- in[...]

Section 3 DESCRIPTION & COMPONENTS or DPE windin g, (c) a cent er tapp ed bat ter y ch arge winding and (d) a 10 Amp center tapped batter y charge winding. Insulation tests of the stator con- sist of (a) testing all windings to ground, (b) testing between isolated windings, and (c) testing between parallel windings. Figure 3-9 is a pictor ial r[...]

Section 3 DESCRIPTION & COMPONENTS 3. Repeat Step 1 at Pin Location 8 (Wire 55) and Stator Lead 11. F or the follo wing steps (4 through 6) an additional paper clip (or similar item) will be needed: 4. Inser t a paper clip into Pin Location 3 (Wire 55A). Connect the red tester probe to the paper clip. Inser t additional paper clip into Pin Loca[...]

Section 4 ENGINE DC CONTROL SYSTEM PRINTED CIRCUIT BO ARD GENERAL: The printed board is responsible for cranking, star tup, running and shutdown operations. The board intercon- nects with other components of the DC control system to turn them on and off at the proper times. It is pow- ered by fused 12 VDC power from the unit battery . CIRCUIT BOARD[...]

Section 4 ENGINE DC CONTROL SYSTEM P age 17 V OL T AGE REGULA T OR TERMINAL BOARD (TB1) TERMINAL BOARD (TB2) ST AR T STOP RELA Y (SSR) ST AR TER CONT ACT OR RELA Y (SCR) IDLE CONTROL TRANSFORMERS (ICT) PRINTED CIRCUIT BOARD 10 AMP FUSE (F1) LOCA TED IN REAR OF CONTROL P ANEL DIODE (D1) RESIST OR (R1) CONNECT OR (C2) CONNECT OR (C1) 50 AMP CIRCUIT B[...]

Section 4 ENGINE DC CONTROL SYSTEM PIN LOCA TION 6 PIN LOCA TION 7 C1 FEMALE SIDE C2 FEMALE SIDE C1 MALE SIDE C2 MALE SIDE PIN LOCA TION 1 PIN LOCA TION 12 2 77A 66A 55A 44S 11S 0 4 77 66 55 6 PIN LOCA TION 7 PIN LOCA TION 6 0 4 77 66 55 6 2 77A 66A 55A 44S 11S PIN LOCA TION 6 PIN LOCA TION 7 PIN LOCA TION 1 PIN LOCA TION 12 13 86 167 0 15 18 0 13 [...]

NO TES P age 19[...]

Section 4 ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION - REST : Batter y voltage is supplied to components of the control system from the unit BA TTER Y via the RED batter y cable connected to the contacts of the star ter contactor (SC), wire 13, a 10 Amp fuse (F1), and Wire 15. Wire 13 is unfused batter y supply voltage and is connected to the conta[...]

Section 4 ENGINE DC CONTROL SYSTEM P age 21 Wire 15 12 VDC fused batter y supply v oltage is supplied to the normally open contacts of the SSR. One set of nor mally open contacts are connected to Wire 15B, the other set of nor mally open contacts are connected to Wire 14. The SSR is de-energized and no v oltage is av ailable through the contacts. W[...]

Section 4 ENGINE DC CONTROL SYSTEM P age 22 VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44[...]

Section 4 ENGINE DC CONTROL SYSTEM P age 23 VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44[...]

Section 4 ENGINE DC CONTROL SYSTEM P age 24 VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44[...]

Section 4 ENGINE DC CONTROL SYSTEM P age 25 VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44[...]

Section 4 ENGINE DC CONTROL SYSTEM P age 26 VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44[...]

Section 4 ENGINE DC CONTROL SYSTEM P age 27 VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44[...]

The “Flow Char ts” in this section may be used in conjunction with the “Diagnostic T ests” of Section 6. Numbered tests in the Flow Char ts correspond to identically numbered tests of Section 6. Problems 1 through 5 apply to the A C generator only . Beginning with Problem 5, the engine DC control sys- tem is dealt with. Section 5 TROUBLESHO[...]

Section 5 TROUBLESHOO TING FLO WCHARTS P age 29 TEST 2 - CHECK MAIN CIRCUIT BREAKER TEST 3 - TEST EXCIT A TION CIRCUIT BREAKER TEST 4 - PERFORM FIXED EXCIT A TION / RO T OR AMP DRA W TEST 9 - TEST ST A TOR TEST 11 - EXCIT A TION WIRING TEST 6 - WIRE CONTINUITY TEST 8 - DIODE/RESIST OR INSULA TION RESIST ANCE TEST P AGE 13 INSULA TION RESIST ANCE TE[...]

Section 5 TROUBLESHOO TING FLO WCHARTS P age 30 TEST 4 - PERFORM FIXED EXCIT A TION / RO T OR AMP DRA W TEST 9 - TEST ST A TOR DPE WINDING CHECK V OL TMETER FUSES - VERIFY AMP METER FUNCTIONS INSULA TION RESIST ANCE TEST P AGE 14 INSULA TION RESIST ANCE TEST P AGE 13 TEST 14 - CHECK RO T OR ASSEMBL Y REP AIR OR REPLACE REP AIR OR REPLACE BAD GOOD B[...]

Section 5 TROUBLESHOO TING FLO WCHARTS P age 31 TEST 17 - CHECK BA TTER Y CHARGE OUTPUT TEST 19 - CHECK BA TTER Y CHARGE RECTIFIER TEST 9 - TEST ST A TOR INSULA TION RESIST ANCE TEST P AGE 13 REP AIR OR REPLACE REP AIR OR REPLACE REPLACE FINISHED GOOD GOOD GOOD BAD BAD BAD BAD Problem 4 - No Battery Char ge Outp ut TEST 18 - CHECK 10A BA TTER Y CHA[...]

Section 5 TROUBLESHOO TING FLO WCHARTS P age 32 BAD REP AIR WIRING GOOD BAD TEST 21 - CHECK 10 AMP FUSE TEST 26 - CHECK ST ARTER CONT ACT OR RELA Y (SCR) TEST 27 - CHECK ST ART -R UN-STOP SWITCH (SW1) GOOD TEST 28 - CHECK ST ART -R UN-STOP SWITCH (SW1) WIRING TEST 22 - CHECK BA TTER Y & CABLES TEST 23 - CHECK V OL T AGE A T ST ARTER CONT ACT OR[...]

Section 5 TROUBLESHOO TING FLO WCHARTS P age 33 BAD BAD BAD BAD PULL OUT ADJUST AND RE-TEST REP AIR OR REPLACE FSS REP AIR OR REPLACE REP AIR OR REPLACE REP AIR OR REPLACE REPLACE REPLACE OFF OFF TURN ON ON TURN OFF REPLACE PRINTED CIRCUIT BOARD GOOD GOOD GOOD GOOD SP ARK GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD TEST 29 - CHECK SP ARK CHECK FUE[...]

Section 5 TROUBLESHOO TING FLO WCHARTS P age 34 REP AIR OR REPLACE BAD REP AIR OR REPLACE BAD REP AIR OR REPLACE BAD GOOD GOOD GOOD GOOD TEST 29 - CHECK SP ARK CHECK FUEL SUPPL Y TEST 38 - CHECK FUEL PUMP CHECK CHOKE POSITION AND OPERA TION TEST 30 - CHECK SP ARK PLUG TEST 35 - CHECK AND ADJUST IGNITION MAGNET OS TEST 39 - CHECK CARBURETION TEST 40[...]

Section 5 TROUBLESHOO TING FLO WCHARTS P age 35 GOOD BAD TEST 50 - CHECK WIRE 167 REPLACE BAD REPLACE BAD REPLACE BAD CORRECT WIRING BAD REPLACE BAD REP AIR OR REPLACE REP AIR OR REPLACE WIRE 14 REP AIR OR REPLACE REP AIR OR REPLACE BAD REPLACE REPLACE GOOD GOOD GOOD (WITH HM) GOOD (WITHOUT HM) GOOD GOOD GOOD BAD BAD GOOD GOOD FUSE BLOWS UPON INST [...]

Section 5 TROUBLESHOO TING FLO WCHARTS P age 36 ON GOOD GOOD OFF BAD BAD TEST 1 - CHECK NO-LOAD VOL T AGE & FREQUENCY TEST 51 - CHECK WIRES 11S / 44S GO T O PROBLEM 2 REP AIR OR REPLACE CHECK T O SEE IF RED LED ON CIRCUIT BOARD IS “ ON” Problem 11 - Unit Over speeds PRODUCING V OL T AGE REPLACE CIRCUIT BOARD NO V OL T AGE TEST 5 - CHECK STE[...]

Section 6 DIA GNOSTIC TESTS P age 37 INTRODUCTION The “Diagnostic T ests” in this chapter may be per - f or med in conjunction with the “Flow Char ts” of Section 5. T est numbers in this chapter correspond to the numbered tests in the “Flow Char ts”. T ests 1 through 19 are procedures Inv olving problems with the generator's A C ou[...]

00.00 C .B. 20/30A Figure 6-8. – 20/30 Amp Breaker T est P oints TES T 3 - TEST EXC IT A TION CIR CUIT BRE AKE R PROCEDURE: 1. With the generator shut down f or at least two min utes, locate the Excitation Circuit Breaker in the control panel. Disconnect wires from the breaker , to prev ent interaction. 2. Set a volt meter to measure resistance .[...]

Section 6 DIA GNOSTIC TESTS P age 39 9. Shutdown the generator . 10. Reconnect Wire 2 to the Excitation Circuit Breaker . 11. Connect one m eter te st lead to Wire 11S lo cated i n the s ix pin connector previously remov ed from the V oltage Regulator . Connect the other meter test lead to Wire 44S located in the six pin connector previously remov [...]

TEST 5 - CHECK STEPPER MO T OR CONTROL PROCEDURE: 1. Remov e air cleaner cover to access stepper motor . 2. Physically g rab the throttle and verify the stepper motor , linkage and throttle do not bind in any way , if any binding is felt repair or replace components as needed. Some resistance should be felt as the stepper motor mo ves through it&ap[...]

Section 6 DIA GNOSTIC TESTS P age 41 TERMINAL BLOCK (TB1) 1 2.00 86 15B 167 BLK 0 229 83 BLK TR2 TR1 Figure 6-5. – T esting Wire 15B TB1 J2 HARNESS CONNECT OR 00.00 86 15B 167 BLK 0 229 83 BLK TR2 TR1 J2-1 J2-12 MAKE SURE THE TEST PROBE CONNECT OR IS MAKING CONT ACT WITH THE CONNECTOR. DOUBLE CHECK TO MAKE SURE THA T THE TIP IS SHARP . Figure 6-6[...]

WIRING DIAGRAM 30 86 87a 85 87 85 87a 30 86 87 16 15 17 13 16 Figure 6-13. – Star ter Contactor Relay R1 D2 4 14 14 4 3.0 vdc Figure 6-14. – T esting Field Boost TEST 8 - DIODE/RESIST OR PROCEDURE: 1. Set volt meter to the diode test r ange. 2. Disconnect the six pin connector from the V oltage Regulator . 3. Disconnect Connector C1. See P age [...]

Section 6 DIA GNOSTIC TESTS P age 43 D2 4 14 WIRE 14 REMO VED 14 4 R1 25 ohm Figure 6-17. – Diode T est Step 9 10. Connect one meter test lead to the top ter minal of the resistor (R1). Connect the other meter test lead to the ground ter minal. INFINITY or an open condition should be measured. 11. Reconnect the six pin connector, reconnect the C1[...]

12. Connect the meter test leads across Stator lead 2 (Pin 6) at the C1 connector female side and frame ground. Be careful not to damage the pin connectors with the test leads, use paper clips - do not force probes into connectors. See Figure 6-18. INFINITY should be read. 13. Connect the meter test leads across Stator lead 66 (Pin 9) at the C1 con[...]

Section 6 DIA GNOSTIC TESTS P age 45 TEST 11 - EXCIT A TION WIRING PROCEDURE: 1. Set a voltmeter to measure resistance . 2. Disconnect Connector C1. See P age 17 for connector location. 3. Locate the male side of the connector located on the bottom of the control panel. See Figure 6-19. Connect one meter test lead to Pin 6 Wire 2, it ma y be helpfu[...]

Section 6 DIA GNOSTIC TESTS P age 46 BR USHES Figure 6-21. – Br ush Location 2. Remov e Wire 4 from the positiv e (+) brush ter minal. 3. Remov e the ground wire (0) from the negative (-) brush. 4. Remov e the br ush holder , with brushes. 5. Inspect the brushes for excessiv e wear , damage, cracks, chip - ping, etc. 6. Inspect the brush holder ,[...]

P age 47 Section 6 DIA GNOSTIC TESTS 2. If load is within limits, but frequency and voltage still drop excessiv ely , refer back to Flo w Char t. TEST 17 - CHECK B A TTER Y CHARGE OUTPUT PROCEDURE: 1. Disconnect Wire 15 (center terminal) from the Battery Charge Rectifier 2 (BCR2), which is located under BCR1. They are stack ed. See Page 17 f or BCR[...]

Shor t to Ground: 4. Set the VOM to measure resistance. Connect the positive (+) test lead to the case housing of the BCR. Connect the negative (-) test lead to an outer ter minal. INFINITY should be mea - sured. Now connect the negative test lead to the BCR center terminal. INFIN ITY should be measured. Next, connect the negative test lead to the [...]

Section 6 DIA GNOSTIC TESTS P age 49 measure at the batter y ter minals during cranking. If battery voltage is below 11 v olts DC, recharge/replace batter y . If bat- ter y or cables are still suspected, connect an alter nate battery and cables to the generator and retest. 2. Use a bat ter y hydr omet er to te st the ba tte r y for (a ) s tat e o f[...]

3. A defectiv e Star ter Motor switch. 4. Broken, damaged or weak magnets . 5. Star ter drive dir ty or binding. PROCEDURE: The batter y should hav e been checked prior to this test and should be fully charged. Set a voltmeter to measure DC voltage (12 VDC). Connect the meter positiv e (+) test lead to the Star ter Contactor stud which has the smal[...]

Section 6 DIA GNOSTIC TESTS P age 51 Figure 6-32. – T achometer TEST BRA CKET: A star ter motor test brack et may be made as shown in Figure 6-33. MET AL STOCK 1/4" THICK STEEL 12" 1.0" 4" 2" 2.625" 3.5" 0.5" 0.5" DRILL TW O HOLES — 1/2" FOR ST ARTER MOUNTING BRACKET DRILL TW O HOLES — 1/2&quo[...]

Section 6 DIA GNOSTIC TESTS P age 52 Ground. 12 VDC should be measured. Reconnect Wire 13 to the SCR. If 12 VDC is NO T measured on Wire 13 Stop T esting and repair or replace Wire 13 between the Star ter Contactor (SC) and the Star ter Contactor Relay (SCR). Note: Jumper leads ma y be used if necessary . 4. Set voltmeter to measure resistance . 5 [...]

Section x xxxxxxxxxxxxxxxxxxxxxxxxxx P age 53 Section 6 DIA GNOSTIC TESTS P age 53 5. Set voltmeter to measure DC v oltage. 6 . Remov e Wire 15 from the Star t-Run-Stop Switch (SW1). Connect the positive meter test lead to Wire 15. Connect the negative meter test lead to frame ground. 12 VDC should be measured. RESUL TS: Repair or replace any wir i[...]

TEST 31 - REMO VE WIRE 18 / SHUTDO WN LEAD PROCEDURE: 1. Disconnect Wire 18 from the Stud located abov e the oil cooler that extends out F rom the shrouding. 2. P erform T est 29 again checking f or Spar k. RESUL TS: Ref er back to Flow Chart. WIRE 18 SHUTDO WN LEAD Figure 6-40. – Wire 18 TEST 32 - TEST ST ART ST OP RELA Y (SSR) PROCEDURE: 1. Set[...]

Section 6 DIA GNOSTIC TESTS P age 55 SSR 15B 14 13 9 10 12 5 1 2 6 4 8 229 0 18 14 TEST POINTS A TEST POINTS B JUMPER LEAD ADDED T O GROUND TEST POINTS C 15 15 15 Figure 6-43. – Star t Stop Relay (SSR) Energized TEST 33 - TEST WIRE 167 PROCEDURE: 1. Set a voltmeter to measure DC v oltage. 2. Remov e the J2 connector from the circuit board. Connec[...]

TEST 34 - TEST ST ART ST OP RELA Y WIRING PROCEDURE: 1. Set voltmeter to the diode test r ange. 2. Disconnect Wire 229 from the Star t Stop Relay (SSR). 3. Connect the positive meter test lead to Wire 229 previous - ly remov ed. Connect the negative meter test lead to frame ground. See Figure 6-47. Place the Star t-Run-Stop Switch to the star t pos[...]

Section 6 DIA GNOSTIC TESTS P age 57 9. Now check the flywheel magnet by holding a screwdriver at the extreme end of its handle and with its point down. When the tip of the screwdriver is mov ed to within 3/4 inch (19mm) of the magnet, the blade should be pulled in against the magnet. 10. No w check the flywheel ke y . The flywheel’ s taper is lo[...]

PROCEDURE: 1. Remov e the fuel line from the fuel filter on the inlet side of the carburetor . Use a suitable catch can to catch fuel. 2. Crank the engine over , fuel should flow from the fuel line. If fuel does not flow , verify that fuel is availab le to the pump. If fuel is av ailable to the pump inspect the fuel filter , pulse line, and or repl[...]

Section 6 DIA GNOSTIC TESTS P age 59 TORQ UE SPECIFICA TION ROCKER ARM J AM NUT 168 inch-pounds (19 Nm) CROW'S FOOT Figure 6-52 – Tightening the Jam Nut INST ALL ROCKER ARM CO VER 1. Us e a n ew r ock er a r m cove r g as ke t. In s ta ll th e r ocke r a r m cov er and retain with four scre ws. RESUL TS: Adjust valv es t o specification and [...]

• Loose cylinder head bolts. • F ailed cylinder head gasket. • Burned valv es or valv e seats. • Insufficient v alve clearance . • W ar ped cylinder head. • W ar ped v alve stem. • W or n or broken piston ring(s). • W or n or damaged cylinder bore. • Brok en connecting rod. • W or n valv e seats or v alves. • W or n valv e gui[...]

Section 6 DIA GNOSTIC TESTS P age 61 RESUL TS: 1. If the SSR measures continuity or zero resistance it is shor ted to ground and should be replaced. 2. If the SSR resistance is correct refer to flo w char t. 1 00 ohm SSR 15B 14 13 9 10 12 5 1 2 6 4 8 229 0 18 14 15 15 15 Figure 6-54. – T esting Star t Stop Rela y (SSR) TEST 44 - TEST ST ARTER CON[...]

RESUL TS: 1. If continuity or zero was measured in Step 3 or Step 4 replace the FSS. 2. (Units without Hourmeter) If correct resistance was measured refer to flow char t, repair or replace Wire 14 between the FSS and Resistor (R1). 3. (Units with Hourmeter) Refer back to flo w char t. TEST 48 - CHECK HOURMETER PROCEDURE: 1. Disconnect Wire 14 from [...]

Connect one meter test lead to pin location J2-10 Wire 44S of the c onnector ju st removed. Be carefu l not to damage th e pin connectors with the test leads. Connect the other m eter test lead to Wire 44S at T erminal Block 2 (TB2). CONTINUITY should be measured. 3. Connect one meter test lead to pin location J2-12 Wire 11S. Be careful not to dama[...]

J2 HARNESS CONNECT OR SW2 00.00 J2-1 J2-12 MAKE SURE THE TEST PROBE CONNECT OR IS MAKING CONT ACT WITH THE CONNECTOR. DOUBLE CHECK TO MAKE SURE THA T THE TIP IS SHARP . 0 83 Figure 6-60. – Check Idle Control Wiring RESUL TS: Repair or replace wir ing as needed. Refer back to the flow chart. TEST 54 - CHECK IDLE CONTROL TRANSFORMERS (ICT) PROCEDUR[...]

PROCEDURE: 1. Set a voltmeter to measure resistance . 2. Disconnect the J2 connector from the printed circuit board. 3. Connect one meter test lead to Wire TR2 at T er minal Block 1 (TB1). See Figure 6-62. Connect the other meter test lead to pin location J2-6 on the J2 Connector previously remov ed. Be careful not to damage the pin connectors with[...]

MAJOR DISASSEMBL Y ST A TOR, R O T OR, AND ENGINE REMO V AL. Ref erence Figures A and B on P ages 68-71 f or com- ponent location. 1. Disconnect and remo ve the battery (Figure B , Item #15) from the generator . 2. Remov e Fuel T ank (Figure B, Item #4). Use proper saf ety pre- cautions when handling gasoline. Figure 7-1. – Fuel T ank Removed 3 .[...]

Section 7 DISASSEMBL Y AND EXPLODED VIEWS P age 67 6. Remov e Stator . Disconnect Wire 4 and Wire 0 from the brush assembly , Figure A, Item 21. Remove the br ush assembly . Remov e the four stator hold down bolts, Figure A, Item 12. Lift the rear end of the alter nator up to clear the muffler frame from the rubber alter nator mount, place a 2x4 un[...]

Section 7 DISASSEMBL Y AND EXPLODED VIEWS P age 68 10 33 39 24 14 23 46 31 13 31 39 17 28 42 43 44 19 32 10 17 16 9 3 5 30 20 1 7 25 40 19 32 22 24 26 31 36 28 32 31 28 27 45 29 18 28 10 40 41 30 11 12 21 4 34 32 15 37 6 2 35 29 8 38 Generator – Figure A[...]

Section 7 DISASSEMBL Y AND EXPLODED VIEWS P age 69 ITEM QTY . DESCRIPTION 1 1 AD APT OR, ENGINE 2 1 ST A T OR 3 1 ASSEMBL Y , RO T OR W/F AN 4 1 CARRIER, REAR BEARING 5 1 EXHA UST MANIFOLD 6 1 MUFFLER 7 1 GASKET , EXHAUST 8 1 CO VER, AL TERNA TOR AIR INT AKE 9 1 BEARING 10 3 5/16 SPECIAL LOCK W ASHER 11 1 SCREW IHHC 3/8-24 X 15.50 G5 12 4 SCREW IHH[...]

Section 7 DISASSEMBL Y AND EXPLODED VIEWS P age 70 22 21 26 30 28 5 6 7 8 9 14 32 42 24 26 27 31 29/51 29 5 19 18 17 20 16 10 1 37 3 11 12 13 33 35 7 7 6 36 34 23 39 38 41 40 39 17 2 44 43 46 25 17 6 7 47 48 49 50 52 7 6 36 Detail of Batter y T ra y POWER WIRE TO ENGINE 4 45 CONTROL P ANEL 15 Frame, Handle & Wheels – Figure B[...]

Section 7 DISASSEMBL Y AND EXPLODED VIEWS P age 71 ITEM QTY . DESCRIPTION 1 4 SCREW HHC M6-1.0 X 55 2 4 R UBBER T ANK MOUNT 3 1 CAP , FUEL WITH GA UGE & VENT 4 1 KIT , FUEL T ANK 5 4 NUT HEX M8-1.25 6 10 W ASHER LOCK M8-5/16 7 14 W ASHER FLA T 5/16 8 1 BRA CKET BA TTER Y 9 2 BOL T ,BA TTER Y J-BOL T 10 2 SCREW HHC 1/4-20 X 3/4 G5 11 2 W ASHER F[...]

Section 8 ELECTRICAL D A T A P age 72 GOVERNOR ACTU A TOR GREEN WHITE Y X OFF ON J2 J1 + - 2 22 77A 66A 11 BA 44S 11S 6 44 REGULA TOR VOL T AGE WHITE Y X G 30A TWISTLOK 120/240V 120V/20A HOT HO T 3 1 WHITE WHITE 5 LINE 4 LOAD 2 C.B. 30A C.B. 30A C.B. 20A C.B. 20A C.B. 30A 30A C.B. TRANSFORMERS IDLE CONTROL CONTROL ON/OFF IDLE 0 LOP FSS SP2 IM2 D IM[...]

Section 8 ELECTRICAL D A T A P age 73 GOVERNOR ACTU A TOR GREEN WHITE Y X OFF ON J2 J1 + - 2 22 77A 66A 11 BA 44S 11S 6 44 REGULA TOR VOL T AGE WHITE Y X G 30A TWISTLOK 120/240V 120V/20A HOT HO T 3 1 WHITE WHITE 5 LINE 4 LOAD 2 C.B. 30A C.B. 30A C.B. 20A C.B. 20A C.B. 30A 30A C.B. TRANSFORMERS IDLE CONTROL CONTROL ON/OFF IDLE 0 LOP FSS SP2 IM2 D IM[...]

VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44B 11B 11B 0 11A 44A 22 20A C.B. 20A 30A C.B.[...]

P age 75 Section 8 ELECTRICAL D A T A VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GOVERNOR 0 0 44C 22 11C 22 C.B. 0 0 0 0 22 22 22 44D 11D 44B 11B [...]

Section 8 ELECTRICAL D A T A P age 76 GOVERNOR ACTU A TOR GREEN WHITE Y X OFF ON J2 J1 + - 2 22 77A 66A 11 BA 44S 11S 6 44 REGULA TOR VOL T AGE WHITE Y X G 30A TWISTLOK 120/240V 120V/20A HOT HO T 3 1 WHITE WHITE 5 LINE 4 LOAD 2 C.B. 30A C.B. 30A C.B. 20A C.B. 20A C.B. 30A 30A C.B. TRANSFORMERS IDLE CONTROL CONTROL ON/OFF IDLE 0 LOP FSS SP2 IM2 D IM[...]

Section 8 ELECTRICAL D A T A P age 77 GOVERNOR ACTU A TOR GREEN WHITE Y X OFF ON J2 J1 + - 2 22 77A 66A 11 BA 44S 11S 6 44 REGULA TOR VOL T AGE WHITE Y X G 30A TWISTLOK 120/240V 120V/20A HOT HO T 3 1 WHITE WHITE 5 LINE 4 LOAD 2 C.B. 30A C.B. 30A C.B. 20A C.B. 20A C.B. 30A 30A C.B. TRANSFORMERS IDLE CONTROL CONTROL ON/OFF IDLE 0 LOP FSS SP2 IM2 D IM[...]

P age 78 VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GO VERNOR 0 0 44C 22 11C 22 C.B . 0 0 0 0 22 22 22 44D 11D 44B 11B 11B 0 11A 44A 22 20A C.B . [...]

P age 79 Section 8 ELECTRICAL D A T A VOL T AGE ELECTRONIC REGULA TOR 11S 162 0 6 44S 4 6 5 4 3 2 1 BCR2 77A 15 66A 5 6 4 10 12 SSR 9 RESET RESET TEST TEST 18 IM2 SP2 IM1 SP1 PRINTED CIRCUIT BOARD CONTROL 12 10 11 9 2 7 8 6 4 5 3 J2 1 J1 15B 83 TR1 0 167 TR2 86 229 44S 11S ACTU A TOR GO VERNOR 0 0 44C 22 11C 22 C.B . 0 0 0 0 22 22 22 44D 11D 44B 11[...]

Section 8 ELECTRICAL D A T A P age 80 ACTU A TOR GOVERNOR SC BLACK 12V BA TTERY SM RED SP2 SP1 IM2 FSS LOP D D IM1 STOP RUN (ST ART) 0 IC PIN # 12 11 10 8 9 7 6 SCR 5 4 3 0 2 1 F1 GND SSR ENGINE WIRING 30A C.B. 22 C.B. 30A 0 22 22 G 0 0 TWISTLOK 120V/30A WHITE 22 0 0 G WHITE TWISTLOK 120V/30A 20A C.B. C.B. 20A C.B. 30A 30A C.B. LOAD LINE WHITE HOT [...]

Section 8 ELECTRICAL D A T A P age 81 ACTU A TOR GOVERNOR SC BLACK 12V BA TTERY SM RED SP2 SP1 IM2 FSS LOP D D IM1 STOP RUN (ST ART) 0 IC PIN # 12 11 10 8 9 7 6 SCR 5 4 3 0 2 1 F1 GND SSR ENGINE WIRING 30A C.B. 22 C.B. 30A 0 22 22 G 0 0 TWISTLOK 120V/30A WHITE 22 0 0 G WHITE TWISTLOK 120V/30A 20A C.B. C.B. 20A C.B. 30A 30A C.B. LOAD LINE WHITE HOT [...]

Section 8 ELECTRICAL D A T A 86 0 14 15 15 167 0 17 16 13 13 22 44 ACTU A TOR J1 44C 0 RESET RESET TEST TEST GFCI 120V 120V/30A TWISTLOK CB1 - 10AMP AUT O RESET BREAKER BCR2 - BA TTERY CHARGE RECTIFIER D2, D3 - ENGINE SHUTDOWN DIODE CB2 - 6AMP AUT O RESET BREAKER BCR1 - BA TTERY CHARGE RECTIFIER, 10A 30A LEGEND BA - BRUSH ASSEMBL Y F1 - 10A FUSE D1[...]

Section 8 ELECTRICAL D A T A CIRCUIT 16 CIRCUIT 14 CIRCUIT 12 CIRCUIT 8 CIRCUIT 6 MAIN 2 CIRCUIT 2 CIRCUIT 4 CIRCUIT 10 NEUTRAL NEUTRAL NEUTRAL CIRCUIT 12 CIRCUIT 14 CIRCUIT 16 CIRCUIT 8 NEUTRAL NEUTRAL CIRCUIT 6 NEUTRAL CIRCUIT 10 MAIN 1 GROUND NEUTRAL CIRCUIT 9 NEUTRAL NEUTRAL NEUTRAL NEUTRAL CIRCUIT 13 CIRCUIT 11 CIRCUIT 3 CIRCUIT 1 CIRCUIT 7 CI[...]

Section 8 ELECTRICAL D A T A P age 84 INTERCONNECTION DRA WING – 17.5 KW GENERA T OR CONNECTED T O THE EXTERNAL CONNECTION BO X, MANU AL TRANSFER SWITCH AND HOME’S MAIN ELECTRICAL DISTRIBUTION P ANEL[...]

P age 85 NO TES[...]

GENERA T OR SPECIFICA TIONS MODEL GPS 12500 GPS 15000 GPS 17500 Model # 004451 004986 004582 004987 005209 004583 005308 Rated Max. P ower 12.5 kW 15.0 kW 17.5 kW Surge P ower 18.75 kW 22.5 kW 26.25 kW Rated A C V oltage 120/240 120/240 120/240 Rated Max A C Load Current @ 240V 52.0 Amps 62.5 Amps 72.9 Amps Current @ 120V 104.0 Amps 125.0 Amps 145.[...]

Section 9 SPECIFICA TIONS & CHARTS P age 87 Flywheel Nut 150 ft. lbs. Cylinder Head Bolts 22 ft. lbs. V alve Cover Bolts 4.8-5.5 ft. lbs. Rocker Arm Jam Nut 14 ft. lbs. Ignition Coil 9 ft. lbs. Intake Manifold 14 ft. lbs. Exhaust Manifold 14 ft. lbs. Stator Bolt 12 ft. lbs. Rotor Bolt 30 ft. lbs. Spark Plug 15 ft. lbs. Starter Bracket T o Block[...]

www .guardiangenerators.com POR T ABLES PO BO X 297 • WHITEW A TER, WI 53190 www .guardiangenerators.com P/N OF7713 REV . A Printed in the USA 6.06 MODELS: 4451 & 4986 (12,500 Watt) 4582 & 4987 (15,000 Watt) 4583 (17,500 Watt) 5209 (15,000 Watt) 5308 (17,500 Watt) UL TRA SOURCE POR T ABLE GENERA TOR DIAGNOSTIC REP AIR MANUAL 0F7713 Cover-[...]