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Guardian Diagnostic Generator 4451 4986 4582 Service Manual
MODELS:
4451 & 4986 (12,500 Watt)
4582 & 4987 (15,000 Watt)
4583 (17,500 Watt)
Manuals Includes info on:
Safety .................. Inside Front Cover (IFC)
NOTICE TO USERS OF THIS MANUAL ..............................IFC
REPLACEMENT PARTS .....................................................IFC
Table Of Contents ...................................... 1-2
Section 1:
Generator Fundamentals ....................... 3-5
Magnetism..................................................................... 3
Electromagnetic Fields .............................................. 3
Electromagnetic Induction ...................................... 3
A Simple AC Generator ................................................ 4
A More Sophisticated AC Generator......................... 4
Section 2:
Measuring Electricity ............................. 6-8
Meters .......................................................................... 6
The VOM ........................................................................ 6
Measuring AC Voltage .............................................. 6
Measuring DC Voltage .............................................. 6
Measuring AC Frequency ......................................... 6
Measuring Current .................................................... 7
Measuring Resistance ................................................ 7
Electrical Units .......................................................... 8
Ohm's Law .................................................................... 8
Section 3:
Description And Components ............. 9-15
Introduction .............................................................. 9
Engine-Generator Drive System ............................... 9
The AC Generator ....................................................... 9
Rotor Assembly .......................................................... 9
Stator Assembly ........................................................ 10
Brush Holder and Brushes ..................................... 10
Other AC Generator Components ........................ 10
EXCITATION CIRCUIT BREAKER .................................. 10
VOLTAGE REGULATOR .............................................. 11
ADJUSTMENT PROCEDURE ....................................... 11
Circuit Breakers ................................................... 12
Rotor Residual Magnetism ..................................... 12
Field Boost Circuit ................................................... 12
Operation ................................................................... 12
STARTUP ................................................................... 12
ON-SPEED OPERATION .............................................. 12
FIELD EXCITATION ..................................................... 12
AC POWER WINDING OUTPUT .................................. 12
BATTERY CHARGE WINDING OUTPUT ....................... 12
10 Amp BATTERY CHARGE WINDING OUTPUT .......... 12
Insulation Resistance .............................................. 13
The Megohmmeter ................................................... 13
GENERAL .................................................................. 13
TESTING STATOR INSULATION ................................... 13
TESTING ROTOR INSULATION .................................... 13
HI-POT TESTER .......................................................... 13
Stator Insulation Resistance Test .......................... 13
GENERAL .................................................................. 13
TESTING ALL STATOR WINDINGS TO GROUND .......... 14
TEST BETWEEN WINDINGS: ....................................... 14
Rotor Insulation Resistance Test .......................... 15
Cleaning the Generator ......................................... 15
Drying the Generator ............................................. 15
Section 4:
Engine DC Control System .................. 16-27
Printed Circuit Board .............................................. 16
GENERAL .................................................................. 16
CIRCUIT BOARD CONNECTIONS ............................... 16
Dip switch Positions ............................................. 16
Battery ....................................................................... 16
RECOMMENDED BATTERY ........................................ 16
Control Panel Component Identification ...... 17-18
Operational Analysis .......................................... 20-27
CIRCUIT CONDITION - REST ...................................... 20
CIRCUIT CONDITION - START .................................... 22
CIRCUIT CONDITION - RUN ....................................... 24
CIRCUIT CONDITION - STOP ...................................... 26
FAULT SHUTDOWN ................................................... 27
Section 5:
Troubleshooting Flowcharts .......... 28-36
Introduction ............................................................ 28
If Problem Involves AC Output ............................... 28
Problem 1 -
Voltage & Frequency Are Both High or Low .. 28
Problem 2 -
Generator Produces Zero Voltage
or Residual Voltage (2-12 VAC) ...................... 29-30
Problem 3 -
Excessive Voltage/Frequency
Droop When Load is Applied ............................... 30
Problem 4 -
No Battery Charge Output ................................. 31
Problem 5 -
No 10 Amp Battery Charge Output ................... 31
Problem 6 -
Engine Will Not Crank ........................................ 32
Problem 7 -
Engine Cranks But Will Not Start ..................... 33
Problem 8 -
Engine Starts Hard and Runs Rough ................ 34
Problem 9 -
Engine Starts Then Shuts Down ........................ 34
Problem 10 -
10 Amp Fuse (F1) Blowing ..................................... 35
Problem 11 -
Unit Overspeeds .................................................... 36
Problem 12 -
Idle Control “RPM Does Not Decrease” ........... 36
Problem 13 -
Idle Control “RPM Does Not Increase
When Load Is Applied” .......................................... 36
Problem 14 -
Engine “Hunts” / Erratic Idle .............................. 36
Section 6:
Diagnostic Tests ...................................... 37-65
Introduction .............................................................. 37
Test 1 - Check No-Load Voltage and Frequency .. 37
TEST 2 - CHECK MAIN CIRCUIT BREAKER........................ 37
TEST 3- TEST EXCITATION CIRCUIT BREAKER................... 38
TEST 4 - FIXED EXCITATION TEST/ROTOR AMP DRAW ..... 38
TEST 5 - CHECK STEPPER MOTOR CONTROL................... 40
Test 6 - Wire Continuity............................................. 41
Test 7 - Check Field Boost ......................................... 41
TEST 8 - DIODE/RESISTOR................................................ 42
TEST 9 - TEST STATOR ..................................................... 43
TEST 10 - SENSING LEADS............................................... 44
TEST 11 - EXCITATION WIRING........................................ 45
TEST 12 - CHECK BRUSH LEADS...................................... 45
Test 13 - Check Brushes & Slip Rings ........................ 45
Test 14 - Check Rotor Assembly............................... 46
Test 15 - Check Load Voltage & Frequency ........... 46
Test 16 - Check Load Watts & Amperage ................ 46
TEST 17 - CHECK BATTERY CHARGE OUTPUT ................. 47
TEST 18 - CHECK 10 Amp BATTERY CHARGE OUTPUT.... 47
Test 19 - Check Battery Charge Rectifier............... 47
TEST 20 - CHECK 10 AMP CIRCUIT BREAKER .................. 48
Test 21- Check 10 Amp Fuse ....................................... 48
Test 22- Check Battery & Cables .............................. 48
TEST 23- Check Voltage at Starter Contactor ..... 49
Test 24 - Check Starter Contactor......................... 49
Test 25 - Check Starter Motor................................. 49
Conditions Affecting Starter Motor
Performance:.......................................................... 49
CHECKING THE PINION:.............................................. 50
TOOLS FOR STARTER PERFORMANCE TEST: ................. 50
Measuring Current:............................................... 50
Tachometer:............................................................ 50
Test Bracket: ........................................................... 51
Remove Starter Motor:......................................... 51
Testing Starter Motor: ......................................... 51
TEST 26 - Test Starter Contactor Relay (SCR)......... 51
TEST 27- Check Start-Run-Stop Switch ................... 52
TEST 28- Check Start-Run-Stop (SW1) Wiring........... 52
Test 29 - Check Ignition Spark .................................. 53
Test 30 - Check Spark Plugs ...................................... 53
TEST 31 - Remove Wire 18 / Shutdown Lead ............ 54
TEST 32 - TEST START STOP RELAY.................................. 54
TEST 33- TEST WIRE 167 ................................................. 55
TEST 34 - TEST START STOP RELAY WIRING..................... 56
Test 35 - Check and Adjust Ignition Magnetos .... 56
TEST 36: TEST FUEL SHUTOFF SOLENOID......................... 57
TEST 37: TEST FUEL SHUTOFF SOLENOID VOLTAGE ......... 57
TEST 38: CHECK FUEL PUMP........................................... 57
Test 39 - Check Carburetion..................................... 58
Test 40 - Valve Adjustment........................................ 58
Test 41 - Check Engine / Cylinder Leak
Down Test / Compression Test ................................. 59
Test 42 - Check Oil Pressure Switch and Wire 86 .. 60
TEST 43: Check Start Stop Relay (SSR)....................... 60
TEST 44: TEST STARTER CONTACTOR RELAY (SCR).......... 61
TEST 45: CHECK WIRE 15 CIRCUIT.................................. 61
TEST 46: CHECK WIRE 14 CIRCUIT.................................. 61
TEST 47: Check Fuel Shutoff Solenoid..................... 61
TEST 48: CHECK HOURMETER ........................................ 62
TEST 49: CHECK WIRE 15B ............................................. 62
TEST 50: CHECK WIRE 167 ............................................. 62
TEST 51: CHECK Wires 11S & 44S.................................. 62
TEST 52: CHECK IDLE CONTROL SWITCH (SW2).............. 63
TEST 53: CHECK IDLE CONTROL WIRING ........................ 63
Test 54: Check Idle Control Transformers ........... 64
TEST 55: CHECK TR1 & TR2 Wiring ............................... 64
Test 56: CHoKe Test ................................................... 65
Section 7:
Disassembly and Exploded Views ..... 66-71
Major Disassembly..................................................... 66
Generator – Figure A ................................................ 68
Frame, Handle & Wheels – Figure B ......................... 70
Section 8:
Electrical Data......................................... 72-79
Wiring Diagram 12.5 & 15 kW (Units Without
Hourmeter) – Drawing No. 0E0228 .......................... 72
Electrical Schematic 12.5 & 15 kW (Units
Without Hourmeter) – Drawing No. 0E0229-A....... 74
Wiring Diagram 12.5 & 15 kW
(Units With Hourmeter) – Drawing No. 0D4609-D.. 76
Electrical Schematic 12.5 & 15 kW (Units With
Hourmeter) – Drawing No. 0D6297-A ...................... 78
Wiring Diagram 17.5 kW Units –
Drawing No. 0G0731 .................................................. 80
Electrical Schematic 17.5 kW Units –
Drawing No. 0G0733 .................................................. 82
Wiring Diagram, 17.5 kW Manual
Transfer Switch – Drawing No. 0G1065 ................ 83
INTERCONECTION DRAWING – 17.5 KW GENERATOR .... 84
Section 9:
Specifications & Charts ....................... 86-87
Generator Specifications.......................................... 86
Engine Specifications ................................................. 86
Engine Speeds and Voltage Specifications ............. 86
Torque Specifications................................................ 87
TRIM Torque Specifications....................................... 87
Index
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
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