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This is a complete Service Manual for the Guardian Generac Ultra Source Portable Generators  on a CD. This CD is filled with very well detailed easy to read troubleshooting, rebuilding, servicing, maintenance and repair information complete with many charts, diagrams, schematics, specifications and pictures. This manual covers all aspects of servicing this equipment in a very clear and concise format with the convenience of having all this information at your fingertips in the form of a CD. This manual will allow you to completely troubleshoot, disassemble, inspect, repair and reassemble your equipment. Runs on Windows with Adobe.

NOTICE*

The photo depicted is a generalization of the entire series of manuals.

Each individual CD is printed with the information specific to that piece of equipment.

This Manual Applies To The Following Models:

Guardian 4551 & 4986 (12,500 watt)

Guardian 4582 & 4987 (15,000 watt)

Guardian 4583 ( 17,500 watt)

Generac 5209 (15,000 watt)

Generac 5308 (17,500 watt)

The Contents of The Manual Are As Follows

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 Sophisticate d AC Generator .......................... 4

Section 2:

Measuring Electricity .............................. 6-8

Meters ........................................................................... 6

The VOM ......................................................................... 6

Measuring AC Volta ge ............................................... 6

Measuring DC Volta ge ............................................... 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

Batter y ........................................................................ 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 -

Volta ge & Frequency Are Both High or Low ... 28

Problem 2 -

Generator Produces Zero Volta ge

or Residual Volta ge (2-12 VAC) ....................... 29-30

Problem 3 -

Excessive Volta ge/Frequency

Droop When Load is Applied ................................ 30

Problem 4 -

No Batter y Charge Output .................................. 31

Problem 5 -

No 10 Amp Batter y 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 Volta ge 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 Volta ge & 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 Batter y Charge Rectifier................ 47

TEST 20 - CHECK 10 AMP CIRCUIT BREAKER................... 48

Test 21- Check 10 Amp Fuse........................................ 48

Test 22- Check Batter y & Cables............................... 48

TEST 23- Check Volta ge 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 Volta ge Specifications .............. 86

Torque Specifications ................................................. 87

TRIM Torque Specifications ........................................ 87

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