Generac Power Systems 4451 & 4986 Repair Manual
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Generac Power Systems 4451 & 4986 Repair Manual

Ultra source portable generator
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PORTABLES
DIAGNOSTIC
REPAIR MANUAL
ULTRA SOURCE PORTABLE GENERATOR
MODELS:
4451 & 4986 (12,500 Watt)
4582 & 4987 (15,000 Watt)
4583 (17,500 Watt)
5209 (15,000 Watt)
5308 (17,500 Watt)
www.guardiangenerators.com

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Summary of Contents for Generac Power Systems 4451 & 4986

  • Page 1 PORTABLES DIAGNOSTIC REPAIR MANUAL ULTRA SOURCE PORTABLE GENERATOR MODELS: 4451 & 4986 (12,500 Watt) 4582 & 4987 (15,000 Watt) 4583 (17,500 Watt) 5209 (15,000 Watt) 5308 (17,500 Watt) www.guardiangenerators.com...

  • Page 2: Notice To Users Of This Manual

    Throughout this publication, "DANGER!" and "CAUTION!" blocks are used to alert the mechanic to special instructions concerning a particular service or operation that might be hazardous if performed incorrectly or carelessly. PAY CLOSE ATTENTION TO THEM. DangeR! unDeR tHis HeaDing Will be FounD special instRuctions WHicH, iF not coMplieD WitH, coulD Result in peRsonal inJuRY oR DeatH.

  • Page 3: Table Of Contents

    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 ...

  • Page 4: Table Of Contents

    table of contents 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 ...

  • Page 5: Generator Fundamentals

    MAgNETISM Magnetism can be used to produce electricity and electricity can be used to produce magnetism. Much about magnetism cannot be explained by our present knowledge. However, there are certain pat- terns of behavior that are known. Application of these behavior patterns has led to the development of gen- erators, motors and numerous other devices that uti- lize magnetism to produce and use electrical energy.

  • Page 6: A Simple Ac Generator

    section 1 geneRatoR FunDaMentals A SIMPLE AC gENERATOR Figure 1-4 shows a very simple AC Generator. The generator consists of a rotating magnetic field called a ROTOR and a stationary coil of wire called a STATOR. The ROTOR is a permanent magnet which consists of a SOUTH magnetic pole and a NORTH magnetic pole.

  • Page 7: Section 1: Generator Fundamentals

    ENGINE - DIRECT DRIVE BCR2 BCR1 12V DC OUTLET 2. During startup, printed circuit board action controls the START/ STOP RELAY to deliver battery voltage to the ROTOR, via the brushes and slip rings. The battery voltage is called “Field Boost”. Flow of direct current through the ROTOR increases the strength of the magnetic field above that of “residual” magnetism alone. 3. “Residual” plus “Field Boost” magnetism induces a voltage into the Stator excitation (DPE), battery charge and AC Power wind- ings.

  • Page 8: Measuring Electricity

    section 2 MeasuRing electRicitY METERS Devices used to measure electrical properties are called meters. Meters are available that allow one to measure (a) AC voltage, (b) DC voltage, (c) AC frequency, and (d) resistance in ohms. The following apply: • To measure AC voltage, use an AC voltmeter. •...

  • Page 9: Measuring Current

    engine speed governor. For models rated 60 Hertz, the governor is generally set to maintain a no-load fre- quency of about 62 Hertz with a corresponding output voltage of about 124 volts AC line-to-neutral. Engine speed and frequency at no-load are set slightly high to prevent excessive rpm and frequency droop under heavy electrical loading.

  • Page 10: Electrical Units

    section 2 MeasuRing electRicitY Component testing may require a specific resis- tance value or a test for INFINITY or CONTINUITY. Infinity is an OPEN condition between two electrical points, which would read as no resistance on a VOM. Continuity is a CLOSED condition between two elec- trical points, which would be indicated as very low resistance or “ZERO”...

  • Page 11: Description And Components

    INTROdUCTION The generator revolving field (rotor) is driven by an air-cooled engine at about 3600 rpm. The generator may be used to supply electrical power for the operation of 120 and/or 240 volts, 1-phase, 60 Hz, AC loads. ENgINE-gENERATOR dRIVE SYSTEM The generator revolving field is driven by an air- cooled, horizontal crankshaft engine.

  • Page 12: Stator Assembly

    section 3 DescRiption & coMponents Figure 3-2. – The 2-Pole Rotor Assembly STATOR ASSEMbLY The stator can houses and retains (a) dual AC power windings, (b) an excitation winding, and (c) two bat- tery charge windings. A total of thirteen (13) stator leads are brought out of the stator can as shown in Figure 3-3.

  • Page 13: Voltage Regulator

    Figure 3-5. – Excitation Circuit Breaker VOLTAGE REGULATOR: A typical Voltage Regulator is shown in Figure 3-6 (12.5 & 15 kW Units) or Figure 3-7 (17.5 kW Units). Unregulated AC output from the stator excitation winding is delivered to the regulator’s DPE termi- nals, via Wire 2, the Excitation Circuit Breaker and Wire 162, and Wire 6.

  • Page 14: Circuit Breakers

    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 AC voltage of about 252 volts. CIRCUIT BREAKERS: Each individual outlet on the generator is protected by a circuit breaker to prevent overload.

  • Page 15: Insulation Resistance

    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 battery with provided battery charge cables. INSULATION RESISTANCE The insulation resistance of stator and rotor wind- ings is a measurement of the integrity of the insulat- ing materials that separate the electrical windings...

  • Page 16: "Testing All Stator Windings To Ground

    section 3 DescRiption & coMponents or DPE winding, (c) a center tapped battery charge winding and (d) a 10 Amp center tapped battery 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.

  • Page 17: Rotor Insulation Resistance Test

    3. Repeat Step 1 at Pin Location 8 (Wire 55) and Stator Lead 11. For the following steps (4 through 6) an additional paper clip (or similar item) will be needed: 4. Insert a paper clip into Pin Location 3 (Wire 55A). Connect the red tester probe to the paper clip. Insert additional paper clip into Pin Location 6 (Wire 2). Connect the black tester probe to this paper clip. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page. 5. Insert a paper clip into Pin Location 3 (Wire 55A). Connect the red tester probe to the paper clip. Insert additional paper clip into Pin Location 8 (Wire 55). Connect the black tester probe to this paper clip. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page.

  • Page 18: Engine Dc Control System

    section 4 engine Dc contRol sYsteM PRINTEd CIRCUIT bOARd GENERAL: The printed board is responsible for cranking, startup, 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.

  • Page 19: Control Panel Component Identification

    section 4 engine Dc contRol sYsteM CONTROL PANEL COMPONENT IdENTIFICATION Page 17...

  • Page 20: Terminal Block

    section 4 engine Dc contRol sYsteM LOCATION C1 FEMALE SIDE LOCATION LOCATION C2 FEMALE SIDE LOCATION TERMINAL BLOCK (TB1) Page 18 LOCATION LOCATION LOCATION LOCATION LOCATION C1 MALE SIDE LOCATION LOCATION C2 MALE SIDE LOCATION 44S 11S TERMINAL BLOCK (TB2)
  • Page 21 notes Page 19...

  • Page 22: Operational Analysis

    section 4 engine Dc contRol sYsteM BATTERY CHARGE WINDING C1-5 C1-4 C1-3 10A BATTERY CHARGE WINDING C1-10 C1-9 C1-8 ELECTRONIC VOLTAGE REGULATOR CONTROL PRINTED CIRCUIT BOARD Battery voltage is supplied to components of the control system from the unit BATTERY via the RED battery cable connected to the contacts of the starter contactor (SC), wire 13, a 10 Amp fuse (F1), and Wire 15.
  • Page 23 120/240V C1-12 C.B. C2-12 C2-7 C2-5 C2-2 C2-10 C2-4 C2-3 C2-8 C2-1 C2-6 C2-11 C2-9 Wire 15 12 VDC fused battery supply voltage is supplied to the normally open contacts of the SSR. One set of normally open contacts are connected to Wire 15B, the other set of normally open contacts are connected to Wire 14.

  • Page 24: Circuit Condition - Start

    section 4 engine Dc contRol sYsteM BATTERY CHARGE WINDING C1-5 C1-4 C1-3 10A BATTERY CHARGE WINDING C1-10 C1-9 C1-8 ELECTRONIC VOLTAGE REGULATOR CONTROL PRINTED CIRCUIT BOARD With the Start-Run-Stop Switch (SW1) held in the start position, Wire 17 from the Starter Contactor Relay (SCR) is now connected to Wire 0 which is frame ground.
  • Page 25 120/240V C1-12 C.B. C2-12 C2-7 C2-5 C2-2 C2-10 C2-4 C2-3 C2-8 C2-1 C2-6 C2-11 C2-9 With the Start-Run-Stop Switch (SW1) held in the start position, Wire 15 is now connected to Wire 167. Wire 15 supplies fused battery power via Wire 167 to the Printed Circuit Board. This 12 VDC input signals the Printed Circuit Board to internally ground Wire 229 which is connected to the coil of the Start-Stop-Relay (SSR).

  • Page 26: Circuit Condition - Run

    section 4 engine Dc contRol sYsteM BATTERY CHARGE WINDING C1-5 C1-4 C1-3 10A BATTERY CHARGE WINDING C1-10 C1-9 C1-8 ELECTRONIC VOLTAGE REGULATOR CONTROL PRINTED CIRCUIT BOARD Once the engine has started the Start-Run-Stop Switch (SW1) is released and will be in the run position, at this point SW1 is not activated.
  • Page 27 120/240V C1-12 C.B. C2-12 C2-7 C2-5 C2-2 C2-10 C2-4 C2-3 C2-8 C2-1 C2-6 C2-11 C2-9 The printed circuit board is supplied with AC voltage from Wires 11S and 44S, this voltage /frequency signal is used by the printed circuit board for governor control operation. When the Idle Control Switch (SW2) is activated to the “ON”...

  • Page 28: Circuit Condition - Stop

    section 4 engine Dc contRol sYsteM BATTERY CHARGE WINDING C1-5 C1-4 C1-3 10A BATTERY CHARGE WINDING C1-10 C1-9 C1-8 ELECTRONIC VOLTAGE REGULATOR CONTROL PRINTED CIRCUIT BOARD With the Start-Run-Stop Switch (SW1) placed in the Stop position Wire 167 is connected to Wire 0 which is frame ground.

  • Page 29: Fault Shutdown

    120/240V C1-12 C.B. C2-12 C2-7 C2-5 C2-2 C2-10 C2-4 C2-3 C2-8 C2-1 C2-6 C2-11 C2-9 With the generator running if the Low Oil Pressure (LOP) closes Wire 86 will be connected to Wire 0 frame ground. Printed Circuit Board action will open Wire 229 from ground; this action will de-energize the Start-Stop Relay (SSR).

  • Page 30: Troubleshooting Flowcharts

    section 5 tRoublesHooting FloWcHaRts The “Flow Charts” in this section may be used in conjunction with the “Diagnostic Tests” of Section 6. Numbered tests in the Flow Charts correspond to identically numbered tests of Section 6. FREQUENCY GOOD - VOLTAGE & VOLTAGE HIGH FREQUENCY BOTH HIGH OR LOW...

  • Page 31: Generator Produces Zero Voltage Or Residual Voltage (2-12 Vac)

    Problem 2 - Generator Produces Zero Voltage or Residual Voltage (2-12 VAC) TEST 2 - CHECK GOOD MAIN CIRCUIT BREAKER RESET TO “ON” OR REPLACE IF BAD PERFORM FIXED TEST 6 - WIRE CONTINUITY GOOD TEST 7 - FIELD BOOST REPAIR GOOD REPLACE,...

  • Page 32: Excessive Voltage/Frequency Droop When Load Is Applied

    section 5 tRoublesHooting FloWcHaRts Problem 2 - Generator Produces Zero Voltage or Residual Voltage (2-12 VAC) PERFORM FIXED TEST 14 - CHECK ROTOR ASSEMBLY REPAIR REPLACE INSULATION RESISTANCE TEST PAGE 14 Problem 3 - Excessive Voltage/Frequency Droop When Load is Applied TEST 15 - CHECK LOAD VOLTAGE &...

  • Page 33: No Battery Charge Output

    Problem 4 - No Battery Charge Output TEST 17 - TEST 19 - CHECK CHECK BATTERY BATTERY CHARGE CHARGE OUTPUT RECTIFIER GOOD REPLACE FINISHED GOOD Problem 5 - No 10A Battery Charge Output TEST 18 - TEST 19 - CHECK 10A CHECK BATTERY BATTERY...

  • Page 34: Engine Will Not Crank

    section 5 tRoublesHooting FloWcHaRts TEST 21 - CHECK 10 AMP FUSE FUSE BAD REPLACE FUSE FUSE BLOWS TEST 23 - CHECK NO VOLTAGE VOLTAGE AT MEASURED STARTER CONTACTOR 12 VDC MEASURED TEST 24 - CHECK STARTER REPLACE CONTACTOR GOOD TEST 25 - CHECK STARTER MOTOR GOOD MECHANICAL BINDING...

  • Page 35: Engine Cranks But Will Not Start

    Problem 7 - Engine Cranks But Will Not Start CHECK CHECK FUEL FUEL GOOD SHUTOFF SUPPLY VALVE REPLENISH FUEL TURN ON SUPPLY TEST 38 - CHECK GOOD FUEL PUMP REPAIR REPLACE SOLENOID VOLTAGE GOOD TEST 39 - CHECK CARBURETION GOOD TEST 5 - CHECK REPAIR STEPPER...

  • Page 36: Engine Starts Hard And Runs Rough

    section 5 tRoublesHooting FloWcHaRts Problem 8 - Engine Starts Hard and Runs Rough CHECK CHECK CHOKE FUEL POSITION AND GOOD SUPPLY OPERATION LOW FUEL PUSH IN AFTER STARTING REPLENISH FUEL SUPPLY TEST 38 - TEST 39 - CHECK CHECK GOOD CARBURETION FUEL PUMP REPAIR...

  • Page 37: Problem 10 - 10 Amp Fuse (F1) Blowing

    Problem 10 - 10 Amp Fuse (F1) Blowing INSTALL NEW FUSE BLOWS 10 AMP FUSE WHEN RUNNING FUSE IS GOOD BUT BLOWS WHEN PLACED TO START VERIFY START-RUN-STOP SWITCH IS WIRED CORRECTLY (SEE FIGURE 6-46, pg. 55) TEST 46 - CHECK WIRE 14 CIRCUIT CONTINUITY MEASURED...

  • Page 38: Problem 11 - Unit Overspeeds

    section 5 tRoublesHooting FloWcHaRts TEST 1 - CHECK PRODUCING NO-LOAD VOLTAGE VOLTAGE & FREQUENCY VOLTAGE GO TO PROBLEM 2 Problem 12 - Idle Control “RPM Does Not Decrease” VERIFY THAT THERE IS NO LOAD TEST 52 - CHECK ON THE IDLE CONTROL GENERATOR SWITCH...

  • Page 39: Diagnostic Tests

    INTROdUCTION The “Diagnostic Tests” in this chapter may be per- formed in conjunction with the “Flow Charts” of Section 5. Test numbers in this chapter correspond to the numbered tests in the “Flow Charts”. Tests 1 through 19 are procedures Involving problems with the generator's AC output voltage and frequency (Problems 1 through 5 in the “Flow Charts”).

  • Page 40: Test 3- Test Excitation Circuit Breaker

    section 6 Diagnostic tests 00.00 Figure 6-8. – 20/30 Amp Breaker Test Points TEST 3 - TEST EXCITATION CIRCUIT bREAkER PROCEDURE: 1. With the generator shut down for at least two minutes, locate the Excitation Circuit Breaker in the control panel. Disconnect wires from the breaker, to prevent interaction.
  • Page 41 9. Shutdown the generator. 10. Reconnect Wire 2 to the Excitation Circuit Breaker. 11. Connect one meter test lead to Wire 11S located in the six pin connector previously removed from the Voltage Regulator. Connect the other meter test lead to Wire 44S located in the six pin connector previously removed from the Voltage Regulator. See Figure 6-11. Be careful not to damage the pin connectors with the test leads. PIN 1 PIN 2 REGULATOR PIN 3 PIN 4 PIN 5 PIN 6 Figure 6-11.

  • Page 42: Test 5 - Check Stepper Motor Control

    section 6 Diagnostic tests TEST 5 - CHECk STEPPER MOTOR CONTROL PROCEDURE: 1. Remove air cleaner cover to access stepper motor. 2. Physically grab 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 moves through it's travel. 3. Physically move the throttle to the closed position by pushing the throttle down as looking from above. a. Place the idle control switch to off. b. Place the start switch to start and watch for stepper motor movement it should move to the wide open position during cranking.

  • Page 43: Test 6 - Wire Continuity

    TERMINAL BLOCK (TB1) Figure 6-5. – Testing Wire 15B J2-1 J2-12 MAKE SURE THE TEST PROBE CONNECTOR IS MAKING CONTACT WITH THE CONNECTOR. DOUBLE CHECK TO MAKE SURE THAT THE TIP IS SHARP. J2 HARNESS CONNECTOR Figure 6-6. – Testing J2-1 RESULTS: 1. If the stepper motor fails any part of Step 5 replace the stepper motor.

  • Page 44: Test 8 - Diode/Resistor

    section 6 Diagnostic tests WIRING DIAGRAM Figure 6-13. – Starter Contactor Relay Figure 6-14. – Testing Field Boost TEST 8 - dIOdE/RESISTOR PROCEDURE: 1. Set volt meter to the diode test range. 2. Disconnect the six pin connector from the Voltage Regulator. 3. Disconnect Connector C1. See Page 17 for connector location. 4. Disconnect both wires from the Resistor (R1). 5. Connect the positive meter test lead to the top terminal of the diode (D1). Connect the negative meter test lead to the bottom of the diode (D1). See Figure 6-15. INFINITY or an open condi- tion should be measured. Page 42 WIRE 14 REMOVED Figure 6-15. – Diode Test Step 5 6. Connect the positive meter test lead to the bottom terminal of the diode (D1). Connect the negative meter test lead to the top of the diode (D1). Approximately 0.5 Volts should be measured.

  • Page 45: Test 9 - Test Stator

    WIRE 14 REMOVED Figure 6-17. – Diode Test Step 9 10. Connect one meter test lead to the top terminal of the resistor (R1). Connect the other meter test lead to the ground terminal. INFINITY or an open condition should be measured. 11. Reconnect the six pin connector, reconnect the C1 connector, reconnect the two wires removed from the resistor (R1). RESULTS: 1. If the diode or resistor failed any step it should be replaced. TEST 9 - TEST STATOR PROCEDURE: 1. From the 50 Amp circuit breaker, disconnect Wires 11 and 44. 2. From the 50 Amp receptacle disconnect Wire 22. 3. Disconnect Connector C1. See Page 17 for connector location. 4. Set a voltmeter to measure resistance. 5. Connect the meter test leads across Stator leads 11 and 22. Normal power winding resistance should be read. 6. Connect the meter test leads across Stator leads 44 and 22. Normal power winding resistance should be read.

  • Page 46: Test 10 - Sensing Leads

    section 6 Diagnostic tests 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 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.

  • Page 47: Test 11 - Excitation Wiring

    TEST 11 - EXCITATION WIRINg PROCEDURE: 1. Set a voltmeter to measure resistance. 2. Disconnect Connector C1. See Page 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 may be helpful to connect a small jumper lead to the individual pin. Disconnect Wire 2 from the Excitation Circuit Breaker (CB1). Connect the other meter test lead to Wire 2 . See Page 17 for Excitation Circuit Breaker loca- tion. Continuity should be measured.

  • Page 48: Test 14 - Check Rotor Assembly

    section 6 Diagnostic tests BRUSHES Figure 6-21. – Brush Location 2. Remove Wire 4 from the positive (+) brush terminal. 3. Remove the ground wire (0) from the negative (-) brush. 4. Remove the brush holder, with brushes. 5. Inspect the brushes for excessive wear, damage, cracks, chip- ping, etc. 6. Inspect the brush holder, replace if damaged. 7. Inspect the slip rings. a. If slip rings appear dull or tarnished they may be cleaned and polished with fine sandpaper. DO NOT USE ANY METALLIC GRIT TO CLEAN SLIP RINGS.

  • Page 49: Test 17 - Check Battery Charge Output

    2. If load is within limits, but frequency and voltage still drop excessively, refer back to Flow Chart. TEST 17 - CHECk bATTERY CHARgE OUTPUT PROCEDURE: 1. Disconnect Wire 15 (center terminal) from the Battery Charge Rectifier 2 (BCR2), which is located under BCR1. They are stacked. See Page 17 for BCR2 location. BCR2 Figure 6-23. – Testing BCR2 2. Set a voltmeter to measure DC Amps. Connect the positive (+) test lead to the center terminal of the Battery Charge Rectifier. Connect the negative (-) test lead to Wire 15 previously discon- nected.

  • Page 50: Test 20 - Check 10 Amp Circuit Breaker

    section 6 Diagnostic tests Short 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 terminal. INFINITY should be mea- sured. Now connect the negative test lead to the BCR center terminal. INFINITY should be measured. Next, connect the negative test lead to the remaining outer BCR terminal. Once again INFINITY should be measured.

  • Page 51: Test 23- Check Voltage At Starter Contactor

    measure at the battery terminals during cranking. If battery voltage is below 11 volts DC, recharge/replace battery. If bat- tery or cables are still suspected, connect an alternate battery and cables to the generator and retest. 2. Use a battery hydrometer to test the battery for (a) state of charge and (b) condition. Follow the hydrometer manufacturer's instructions carefully. RESULTS: 1. Clean battery posts and cables as necessary. Make sure bat- tery cables are tight. 2. Recharge the battery, if necessary. 3. Replace the battery, if necessary. 4. If battery is good, but engine will not crank, refer back to Flow Charts.

  • Page 52: Checking The Pinion

    section 6 Diagnostic tests 3. A defective Starter Motor switch. 4. Broken, damaged or weak magnets. 5. Starter drive dirty or binding. PROCEDURE: The battery should have been checked prior to this test and should be fully charged. Set a voltmeter to measure DC voltage (12 VDC). Connect the meter positive (+) test lead to the Starter Contactor stud which has the small jumper wire con- nected to the Starter.

  • Page 53: Test Bracket

    Figure 6-32. – Tachometer TEST BRACKET: A starter motor test bracket may be made as shown in Figure 6-33. 2.625" 0.5" 3.5" 1.0" 12" DRILL TWO HOLES — 1/2" FOR STARTER MOUNTING BRACKET DRILL TWO HOLES — 1/2" FOR MOUNTING TACHOMETER TAP FOR 1/4-20 NC SCREWS Figure 6-33.

  • Page 54: Test 27- Check Start-Run-Stop Switch

    section 6 Diagnostic tests Ground. 12 VDC should be measured. Reconnect Wire 13 to the SCR. If 12 VDC is NOT measured on Wire 13 Stop Testing and repair or replace Wire 13 between the Starter Contactor (SC) and the Starter Contactor Relay (SCR). Note: Jumper leads may be used if necessary. 4. Set voltmeter to measure resistance. 5. Remove Wire 13, Wire 16, and Wire 17 from the Starter Contactor Relay (SCR) 6. Connect the meter leads across Terminal 87 and Terminal 30 of the SCR. See Figure 6-35.

  • Page 55: Test 29 - Check Ignition Spark

    5. Set voltmeter to measure DC voltage. 6. Remove Wire 15 from the Start-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. RESULTS: Repair or replace any wiring that did not have continu- ity.

  • Page 56: Test 31 - Remove Wire 18 / Shutdown Lead

    section 6 Diagnostic tests TEST 31 - REMOVE WIRE 18 / SHUTdOWN LEAd PROCEDURE: 1. Disconnect Wire 18 from the Stud located above the oil cooler that extends out From the shrouding. 2. Perform Test 29 again checking for Spark. RESULTS: Refer back to Flow Chart. WIRE 18 SHUTDOWN LEAD Figure 6-40. – Wire 18 TEST 32 - TEST START STOP RELAY (SSR) PROCEDURE: 1. Set a voltmeter to measure DC voltage.

  • Page 57: Test 33- Test Wire 167

    TEST POINTS C TEST POINTS B TEST POINTS A ADDED TO GROUND Figure 6-43. – Start Stop Relay (SSR) Energized TEST 33 - TEST WIRE 167 PROCEDURE: 1. Set a voltmeter to measure DC voltage. 2. Remove the J2 connector from the circuit board. Connect the positive meter test lead to Pin Location J2-5, Wire 167 on the removed harness connector. See Figure 6-44 Connect the negative meter test lead to frame ground. Place the Start-Run- Stop switch (SW1) to start. The engine will crank and 12 VDC should be measured. If 12 VDC is measured, stop testing. If 12...

  • Page 58: Test 34 - Test Start Stop Relay Wiring

    section 6 Diagnostic tests TEST 34 - TEST START STOP RELAY WIRINg PROCEDURE: 1. Set voltmeter to the diode test range. 2. Disconnect Wire 229 from the Start Stop Relay (SSR). 3. Connect the positive meter test lead to Wire 229 previous- ly removed. Connect the negative meter test lead to frame ground. See Figure 6-47. Place the Start-Run-Stop Switch to the start position. The meter should read approximately 1.0 VDC. If the correct voltage is indicated, stop testing.

  • Page 59: Test 36: Test Fuel Shutoff Solenoid

    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 moved to within 3/4 inch (19mm) of the magnet, the blade should be pulled in against the magnet. 10. Now check the flywheel key. The flywheel’s taper is locked on the crankshaft taper by the torque of the flywheel nut. A keyway is provided for alignment only and theoretically carries no load. Note: If the flywheel key becomes sheared or even partially sheared, ignition timing can change. Incorrect timing can result in hard starting or fail- ure to start.

  • Page 60: Test 39 - Check Carburetion

    section 6 Diagnostic tests PROCEDURE: 1. Remove 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 available to the pump. If fuel is available to the pump inspect the fuel filter, pulse line, and or replace the fuel pump. RESULTS: Refer to flow chart. TEST 39 - CHECk CARbURETION PROCEDURE: Before making a carburetion check, be sure the fuel sup- ply tank has an ample supply of fresh, clean gasoline. Check that all shutoff valves are open and fuel flows freely through the fuel line.

  • Page 61: Test 41 - Check Engine / Cylinder Leak Down Test / Compression Test

    toRQue speciFication RocKeR aRM JaM nut 168 inch-pounds (19 nm) CROW'S FOOT Figure 6-52 – Tightening the Jam Nut INSTALL ROCKER ARM COVER 1. Use a new rocker arm cover gasket. Install the rocker arm cover and retain with four screws. RESULTS: Adjust valves to specification and retest. If problem continues, refer to Flow Chart.

  • Page 62: Test 42 - Check Oil Pressure Switch And Wire

    section 6 Diagnostic tests • Loose cylinder head bolts. • Failed cylinder head gasket. • Burned valves or valve seats. • Insufficient valve clearance. • Warped cylinder head. • Warped valve stem. • Worn or broken piston ring(s). • Worn or damaged cylinder bore. •...

  • Page 63: Test 44: Test Starter Contactor Relay (Scr)

    RESULTS: 1. If the SSR measures continuity or zero resistance it is shorted to ground and should be replaced. 2. If the SSR resistance is correct refer to flow chart. Figure 6-54. – Testing Start Stop Relay (SSR) TEST 44 - TEST STARTER CONTACTOR RELAY (SCR) PROCEDURE: 1. Set a voltmeter to measure resistance. 2. Disconnect Wire 15 and Wire 17 from the Starter Contactor Relay (SCR). 3. Connect one meter test lead to the terminal that Wire 15 was removed from. Connect the other meter test lead to the ter- minal that Wire 17 was removed from. Resistance measured should be approximately 75 ohms.

  • Page 64: Test 48: Check Hourmeter

    section 6 Diagnostic tests RESULTS: 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 chart, repair or replace Wire 14 between the FSS and Resistor (R1). 3. (Units with Hourmeter) Refer back to flow chart. TEST 48 - CHECk HOURMETER PROCEDURE: 1. Disconnect Wire 14 from the hourmeter. Install new 10 Amp fuse. Set Start Run Stop Switch (SW1) to start. 2. Check to see if fuse blew open. RESULTS: 1. If fuse did not blow open replace the hour meter. 2. If fuse still blew repair or replace Wire 14 between the Resistor (R1) and the Hour Meter (HM) or between the HM and the Fuel Shutoff Solenoid (FSS). TEST 49 - CHECk WIRE 15b PROCEDURE: 1. Set a voltmeter to measure resistance.

  • Page 65: Test 52: Check Idle Control Switch (Sw2)

    Connect one meter test lead to pin location J2-10 Wire 44S of the connector just removed. Be careful not to damage the pin connectors with the test leads. Connect the other meter test lead to Wire 44S at Terminal Block 2 (TB2). CONTINUITY should be measured. 3. Connect one meter test lead to pin location J2-12 Wire 11S. Be careful not to damage the pin connectors with the test leads. Connect the other meter test lead to Wire 11S at Terminal Block 2 (TB2). CONTINUITY should be measured.

  • Page 66: Test 54: Check Idle Control Transformers

    section 6 Diagnostic tests J2-1 J2-12 MAKE SURE THE TEST PROBE CONNECTOR IS MAKING CONTACT WITH THE CONNECTOR. DOUBLE CHECK TO J2 HARNESS CONNECTOR MAKE SURE THAT THE TIP IS SHARP. Figure 6-60. – Check Idle Control Wiring RESULTS: Repair or replace wiring as needed. Refer back to the flow chart.

  • Page 67: Section 6: Diagnostic Tests

    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 Terminal Block 1 (TB1). See Figure 6-62. Connect the other meter test lead to pin location J2-6 on the J2 Connector previously removed. Be careful not to damage the pin connectors with the test leads. Continuity should be measured. 4. Connect one meter test lead to Wire TR1 at Terminal Block 1 (TB1). See Figure 6-63. Connect the other meter test lead to pin location J2-3 on the J2 Connector previously removed. Be careful not to damage the pin connectors with the test leads.

  • Page 68: Disassembly And Exploded Views

    section 7 DisasseMblY anD exploDeD vieWs MAJOR dISASSEMbLY STATOR, ROTOR, AND ENGINE REMOVAL. Reference Figures A and B on Pages 68-71 for com- ponent location. 1. Disconnect and remove the battery (Figure B, Item #15) from the generator. 2. Remove Fuel Tank (Figure B, Item #4). Use proper safety pre- cautions when handling gasoline. Figure 7-1. – Fuel Tank Removed 3. Remove Control Panel. (Figure B) The front control panel should be removed and Wires 11 & 44 will need to be discon- nected from the 50 Amp circuit breaker and Wire 22 from the...
  • Page 69 6. Remove Stator. Disconnect Wire 4 and Wire 0 from the brush assembly, Figure A, Item 21. Remove the brush assembly. Remove the four stator hold down bolts, Figure A, Item 12. Lift the rear end of the alternator up to clear the muffler frame from the rubber alternator mount, place a 2x4 under the front bear- ing carrier for support. Using a rubber mallet carefully remove the rear bearing carrier, Figure A, Item 4. Rotate the rotor so that the steel laminations face the top and bottom. Remove the stator can. Figure 7-6. – Support Alternator 7. Remove Rotor. Remove rotor bolt, Figure A, Item 11. Cut 2.5 inches from the hex head end of the rotor bolt. Slot the end of the bolt to suit a flat blade screwdriver. Slide the rotor bolt back through the rotor and use a screwdriver to screw it into...

  • Page 70: Generator - Figure A

    section 7 DisasseMblY anD exploDeD vieWs generator – Figure a Page 68...
  • Page 71 iteM QtY. DescRiption ADAPTOR, ENGINE STATOR ASSEMBLY, ROTOR W/FAN CARRIER, REAR BEARING EXHAUST MANIFOLD MUFFLER GASKET, EXHAUST COVER, ALTERNATOR AIR INTAKE BEARING 5/16 SPECIAL LOCK WASHER SCREW IHHC 3/8-24 X 15.50 G5 SCREW IHHC M8-1.25 X 400 G8.8 BRACKET, ALT MOUNTING SCREW HHTT #10-32 X 1.75 SCREW HHTT M8-1.2 X 20 ENGINE MOUNTING PLATE...

  • Page 72: Frame, Handle & Wheels - Figure B

    section 7 DisasseMblY anD exploDeD vieWs Frame, Handle & Wheels – Figure b 11 12 13 POWER WIRE TO ENGINE Detail of Battery Tray Page 70 29/51 CONTROL PANEL...
  • Page 73 iteM QtY. DescRiption SCREW HHC M6-1.0 X 55 RUBBER TANK MOUNT CAP, FUEL WITH GAUGE & VENT KIT, FUEL TANK NUT HEX M8-1.25 WASHER LOCK M8-5/16 WASHER FLAT 5/16 BRACKET BATTERY BOLT,BATTERY J-BOLT SCREW HHC 1/4-20 X 3/4 G5 WASHER FLAT 1/4 WASHER LOCK M6-1/4 NUT HEX 1/4-20 BATTERY CABLE, RED...

  • Page 74: Electrical Data

    section 8 electRical Data Wiring Diagram 12.5 & 15 kW (units Without Hourmeter) – Drawing no. 0e0228 120V/30A 120V/30A TWISTLOK TWISTLOK WHITE WHITE C.B. C.B. ENGINE WIRING BLACK BATTERY Page 72 120V/20A DUPLEX C.B. GOVERNOR ACTUATOR (START) STOP PIN # 120/240V 120V/20A 30A TWISTLOK...
  • Page 75 120/240V 50A OUTLET GREEN WHITE C.B. ON/OFF IDLE CONTROL SWITCH IDLE CONTROL TRANSFORMERS ELECTRONIC GOVERNOR / ENGINE SHUTDOWN P.C.B. 10A AUTO RESET BKR 12Vdc OUTLET electRical Data PIN # PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 LEGEND BA - BRUSH ASSEMBLY CB1 - 5AMP AUTO RESET BREAKER...

  • Page 76: Electrical Schematic 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0229-A

    section 8 electRical Data electrical schematic 12.5 & 15 kW (units Without Hourmeter) – Drawing no. 0e0229-a BATTERY CHARGE WINDING C1-5 C1-4 C1-3 10A BATTERY CHARGE WINDING C1-10 C1-9 C1-8 ELECTRONIC VOLTAGE REGULATOR CONTROL PRINTED CIRCUIT BOARD Page 74 POWER WINDING C1-2 I.C.
  • Page 77 FIELD C1-12 C.B. GOVERNOR ACTUATOR 120/240V 120/240V TWISTLOK C.B. C.B. C2-12 C2-7 C2-5 C2-2 C2-10 C2-4 C2-3 C2-8 C2-1 C2-6 C2-11 BATTERY C2-9 BLACK electRical Data 120V DUPLEX 120V/30A 120V/30A TWISTLOK TWISTLOK C.B. C.B. C.B. LEGEND BA - BRUSH ASSEMBLY BCR1 - BATTERY CHARGE RECTIFIER, 10A BCR2 - BATTERY CHARGE RECTIFIER CB1 - 10AMP AUTO RESET BREAKER...

  • Page 78: Wiring Diagram 12.5 & 15 Kw (Units With Hourmeter) - Drawing No. 0D4609-D

    section 8 electRical Data Wiring Diagram 12.5 & 15 kW (units With Hourmeter) – Drawing no. 0D4609-D 120V/30A 120V/30A TWISTLOK TWISTLOK WHITE WHITE C.B. C.B. ENGINE WIRING BLACK BATTERY Page 76 120V/20A DUPLEX C.B. GOVERNOR ACTUATOR (START) STOP PIN # 120/240V 120V/20A 30A TWISTLOK...
  • Page 79 120/240V 50A OUTLET GREEN WHITE C.B. ON/OFF IDLE CONTROL SWITCH HOURMETER IDLE CONTROL TRANSFORMERS ELECTRONIC GOVERNOR / ENGINE SHUTDOWN P.C.B. 10A AUTO RESET BKR 12Vdc OUTLET electRical Data PIN # PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 LEGEND BA - BRUSH ASSEMBLY...

  • Page 80: Electrical Schematic 12.5 & 15 Kw (Units With Hourmeter) - Drawing No. 0D6297-A

    section 8 electRical Data electrical schematic 12.5 & 15 kW (units With Hourmeter) – Drawing no. 0D6297-a BATTERY CHARGE WINDING C1-5 C1-3 10A BATTERY CHARGE WINDING C1-10 C1-9 C1-8 ELECTRONIC VOLTAGE REGULATOR CONTROL PRINTED CIRCUIT BOARD Page 78 POWER WINDING C1-4 C1-2 I.C.

  • Page 81: Section 8: Electrical Data

    FIELD C1-12 C.B. GOVERNOR ACTUATOR 120/240V 120/240V TWISTLOK C.B. C.B. C2-12 C2-7 C2-5 C2-2 C2-10 C2-4 C2-3 C2-8 C2-1 C2-6 C2-11 C2-9 BATTERY BLACK electRical Data 120V DUPLEX 120V/30A 120V/30A TWISTLOK TWISTLOK C.B. C.B. LEGEND BA - BRUSH ASSEMBLY BCR1 - BATTERY CHARGE RECTIFIER, 10A BCR2 - BATTERY CHARGE RECTIFIER CB1 - 10AMP AUTO RESET BREAKER CB2 - 5AMP AUTO RESET BREAKER...

  • Page 82: Wiring Diagram 17.5 Kw Units - Drawing No. 0G0731

    section 8 electRical Data Wiring Diagram 17.5 kW – Drawing no. 0g0731 120V/30A 120V/30A TWISTLOK TWISTLOK WHITE WHITE C.B. C.B. ENGINE WIRING BLACK BATTERY Page 80 120V/20A 120V/20A DUPLEX GFCI LOAD LINE C.B. C.B. GOVERNOR ACTUATOR (START) STOP PIN # 120/240V (50A/60A) OUTLET 120/240V...
  • Page 83 ON/OFF 12 11 IDLE CONTROL SWITCH ELECTRONIC GOVERNOR / ENGINE SHUTDOWN P.C.B. VOLTAGE REGULATOR IDLE CONTROL TRANSFORMERS 10A AUTO RESET BKR 12Vdc OUTLET section 8 electRical Data STATOR CLOSEST TO BEARING PIN # BATTERY CHARGE RECTIFIER LEGEND BA - BRUSH ASSEMBLY BATTERY CB1 - 6AMP AUTO RESET BREAKER CHARGE...

  • Page 84: Electrical Schematic 17.5 Kw Units - Drawing No. 0G0733

    section 8 electRical Data electrical schematic 17.5 kW – Drawing no. 0g0733 BATTERY CHARGE WINDING C1-5 C1-4 C1-3 10A BATTERY CHARGE WINDING C1-10 C1-9 C1-8 ELECTRONIC VOLTAGE REGULATOR CONTROL PRINTED CIRCUIT 120V 120V GFCI DUPLEX RESET TEST RESET TEST C.B. C.B.

  • Page 85: Wiring Diagram, 17.5 Kw Manual Transfer Switch - Drawing No. 0G1065

    GROUND (GRN) NEUTRAL (WHT) NEUTRAL (WHT) CIRCUIT 9 NEUTRAL (WHT) CIRCUIT 11 NEUTRAL (WHT) CIRCUIT 13 NEUTRAL (WHT) CIRCUIT 15 CIRCUIT 1 (BRN) CIRCUIT 3 (BRN/WHT) CIRCUIT 5 (YEL) CIRCUIT 7 (YEL/WHT) CIRCUIT 9 (LT BLU) CIRCUIT 11 (ORG) CIRCUIT 13 (DRK BLU) CIRCUIT 15 (PNK)

  • Page 86: Interconection Drawing - 17.5 Kw Generator

    section 8 electRical Data inteRconnection DRaWing – 17.5 KW geneRatoR connecteD to tHe exteRnal connection box, Manual tRansFeR sWitcH anD HoMe’s Main electRical DistRibution panel Page 84...
  • Page 87 notes Page 85...

  • Page 88: Specifications & Charts

    section 9 speciFications & cHaRts MoDel Model # Rated Max. Power Surge Power Rated AC Voltage Rated Max AC Load Current @ 240V Current @ 120V Rated Frequency Phase Rated DC Voltage Rated Max DC Load Current @ 12 Volts Rated Horsepower @3600 RPM Displacement...

  • Page 89: Torque Specifications

    TORqUE SPECIFICATIONS Flywheel Nut Cylinder Head bolts Valve Cover bolts Rocker Arm Jam Nut Ignition Coil Intake Manifold Exhaust Manifold Stator bolt Rotor bolt Spark Plug Starter bracket To block TRIM TORqUE SPECIFICATIONS M3-.5 PHILLIPS PAN HEAd SCREw INTO ALUMINUM M6-1 TAPTITE SCREw INTO ALUMINUM 9 M6-1 TAPTITE SCREw INTO wELdNUT M8-1.25 TAPTITE SCREw INTO ALUMINUM...
  • Page 90 PO BOX 297 • WHITEWATER, WI 53190 www.guardiangenerators.com P/N OF7713 REV. A Printed in the USA 6.06...

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