Diagnostic Repair Manual | Guardian Technologies 4390, 4456 instruction

AIR-COOLED

DIAGNOSTIC

REPAIR MANUAL

AUTOMATIC HOME STANDBY GENERATORS	Visit us online at
	www.guardiangenerators.com

Models:

4389, 4758 (6 kW NG, 7 kW LP) 4456, 4759 (12 kW NG, 12 kW LP) 4390, 4760 (13 kW, 15 kW LP)

Image 1

Guardian Technologies 4390, 4456, 4389, 4760, 4759, 4758 manual Diagnostic Repair Manual

Contents

Diagnostic Repair Manual Diagnostic Repair Manual Electrical Formulas Fuel Consumption EngineStator Winding Resistance Values / Rotor Resistance Mounting Dimensions Specifications Major Features Part General Information Item Number IntroductionSerial Number Prepackaged Transfer Switches Transfer Switch / Load CenterSelecting a Location Grounding the Generator Prepackaged Installation Basics Part System Control Interconnections Power Source and Load Lines Fuel Requirements General Meters Visual InspectionVOM Measuring AC Voltage Measuring Current Measuring AC FrequencyMeasuring Resistance Ohms LAW Electrical UnitsAmpere Volt Megohmmeter Insulation ResistanceStator Insulation Resistance Test Test Between Windings Testing ALL Stator Windings to Ground Rotor Insulation Resistance Test Cleaning the GeneratorDrying the Generator LOW OIL Pressure Shutdown High OIL Temperature ShutdownOverspeed Shutdown Overcrank Shutdown OFF Position Control PanelManual Position Auto position To Select Automatic Operation SET Exercise SwitchManual Transfer to Standby Manual Startup Protection Systems Manual Shutdown and Retransfer Back to Utility Automatic Operating Sequences Automatic Operating Parameters SEQ. Condition Action SENSOR, Timer or Other Part AC Generators AC Generator Rotor AssemblyENGINE-GENERATOR Drive System Brush Holder and Brushes Stator AssemblyOther AC Generator Components Excitation Circuit Breaker Main Line Circuit Breaker Voltage Regulator Field Boost Rotor Residual MagnetismField Boost Circuit Operation Troubleshooting Flowcharts Troubleshooting Flowcharts Part Section Section Procedure SafetyTest 1- Check Main Circuit Breaker Discussion Test 3- Test Excitation Circuit Breaker Test 2- Check AC Output VoltageIf a high voltage is indicated, go on to Test Set VOM to AC volts Test 4- Fixed Excitation Test Rotor AMP Draw Test Test 6 Check Field Boost Test 5 Wire Continuity Test 7 Testing the Stator with a VOM Set VOM to the Rx1 scale Test 8 Resistance Check Rotor Circuit Test 9 Check Brushes Slip Rings Remove wire 4 from the voltage regulatorIf continuity was measured in steps 5 and 6 proceed to step Test 12 Check and Adjust Engine Governor Test 10 Test Rotor AssemblyTest 11 Check AC Output Frequency Start the engine, let it stabilize and warm up at no-load Loosen the governor clamp bolt Figure Procedure 7KW Units Test 15 Check for Overload Condition Test 13 Check and Adjust Voltage RegulatorTest 14 Check Voltage Frequency Under Load Test 16 Check Engine Condition Part Type Prepackaged Transfer Switches Enclosure Transfer Mechanism Limit Switches XA1 and XB1Utility Closing Coil C1 Standby Closing Coil C2 Neutral LUG Transfer RelayManual Transfer Handle Terminal Block Utility 1 Fuse HolderTerminals 23 Fuses F1, F2 Operational Analysis Wiring Diagram and Schematic Utility Source Voltage Available Utility Source Power Available Utility Source Voltage Failure Generator Power Available, Waiting to Transfer Transfer Action to Standby Position Transfer to Standby Generator Powering Load Utility Restored, Generator Still Providing Output to Load Utility Restored Utility Restored, Transfer Relay De-energized Utility RESTORED, Transfer Switch DE-ENERGIZED Utility RESTORED, Retransfer Back to Utility Transfer Switch in Utility Transfer Switch in Utility Introduction to Troubleshooting Troubleshooting Flow Charts Part If the generator has been shut down, proceed as follows Test 21- Check Voltage AT Terminal Lugs E1, E2 Test 22 Check Voltage AT Standby Closing Coil C2 Test 23 Test Transfer Relay TR Test 24- Check Manual Transfer Switch OperationNow, connect the VOM test leads across Relay Terminals 1 Continuity Results Test 25- Test Limit Switch XB1 PROCEDURE/RESULTS WIRING/CONNECTIONSTest 27- Check Voltage AT Terminal Lugs N1, N2 Test 29- Check Voltage AT Utility Closing Coil C1 Utility 2 Terminals Test 30 Check Fuses F1 and F2 Test 31 Test Limit Switch XA1 Test 34 Check N1 and N2 Wiring Test 33 Continuity Test of Wiring C2Set the AUTO-OFF-MANUAL switch to the OFF position See Test 32, Step Test 35 Check Transformer TX Transformer TX Part DC Control Transformer TX Terminal Strip / InterconnectionCircuit Board Utility 1 and Utility Description and Components AMP Fuse AUTO-OFF-MANUAL Switch Control Panel Component Identification Circuit Condition Utility Source Voltage Available Operational Analysis Circuit Condition Initial Dropout of Utility Source Voltage Initial Dropout Utility Source Voltage Section Utility Voltage Dropout Engine Cranking Section Circuit Condition Engine Startup and Running Engine Startup and Running Section Initial Transfer to Standby Source Section Circuit Condition Utility Voltage Restored Utility Voltage Restored / RE Transfer to Utility Section Circuit Condition Retransfer to Utility and Engine Shutdown Engine Shutdown Operational Analysis Troubleshooting Flow Charts Part Troubleshooting Flow Charts Section Section Section Section Section Test 43- Test AUTO-OFF-MANUAL Switch Test 41 Check Position of AUTO-OFF Manual SwitchTest 42 TRY a Manual Start Set a VOM to measure DC voltage Replace AUTO-OFF-MANUAL switch, if defective Inspect Battery Cables Test 46- Check BatteryTest Battery State of Charge Test 45- Check 15 AMP Fuse Test Battery Condition Test 47 Check Wire 56 VoltageIf battery voltage is not indicated in , go to Test Test 48- Test Starter Contactor Relay V-TWIN only Starter Contactor Relay Test 49- Test Starter Contactor Shorted, open or grounded armature Test 50- Test Starter MotorConditions Affecting Starter Motor Performance Checking the Pinion Tools for Starter Performance Test TachometerMeasuring Current Test Bracket Remove Starter Motor Testing Starter Motor Test 51 Check Fuel Supply Pressure Testing Starter Motor Performance Disconnect Wire 14 at the Fuel Solenoid FS Test 53 Check Circuit Board Wire OutputSet the AUTO-OFF-MANUAL switch to OFF Test 52 Test Fuel Solenoid Test 55 Check for Ignition Spark Test 54 Check Fuel Solenoid Test 57- Check Engine Compression Test 56 Check Spark PlugsIf sparking occurs but engine still wont start, go to Test Test 59 Check and Adjust Ignition Magnetos Test 58 Check Shutdown WireIf ignition spark still has not occurred, proceed to Test Setting Ignition Magneto Armature Air Gap Check engine crankcase oil level Test 60- Check OIL Pressure Switch WireWith oil level correct, try starting the engine Do the following Switch terminals Test 61- Check High OIL Temperature SwitchReplace switch if it fails the test Remove the High Oil Temperature Switch Procedure Intake and Exhaust Test 62 Check and Adjust ValvesTest 63 Check Fuel Regulator Test 64 Check Battery Charge Output Test 65 Check Transformer TX Voltage Output Test 66 Check AC Voltage AT Battery ChargerSet a VOM to measure AC voltage If voltage was not measured in , go to Test BCR Test 68 Check Battery Charge Winding Harness Test 70 Check Engine RUN Winding Test 69 Check Battery Charger WiringSet VOM to measure frequency 63 HZ should be measured Test 71 Check N1 and N2 Voltage Test 73 Test SET Exercise SwitchAT the Circuit Board Test 75 Check Battery Voltage Circuit Test 74 Check Remote Start Wiring If EquippedTest 76 Check Cranking and Running Circuits Continuity Test 77 Test Exercise Function Part Operational Tests Type Transfer Switches Manual Transfer Switch OperationElectrical Checks Generator Tests Under Load Verify that the AUTO-OFF-MANUAL switch is set to Auto Setting the Exercise TimerChecking Automatic Operation Part Disassembly Remove door Major DisassemblySTATOR/ROTOR/ENGINE Removal Major Disassembly Follow Stator/Rotor/Engine removal procedures, Steps Front Engine AccessReverse the previous steps to re-assemble Part Electrical Data Model Part SCHEMATIC, 7 KW Home Standby Model 4456-0 Part SCHEMATIC, 12 & 15 KW Home Standby Drawing #0D9013-C 1 Part Wiring DIAGRAM, 7 KW Home Standby Drawing #0D9014-B 1 Drawing #0D9014-B 2 Model 4456-1 Part Wiring DIAGRAM, 12 & 15 KW Home Standby Drawing #0D8501-B 1 Drawing #0D8501-B 2 Part Electrical Data Part Page Page Xxxxxxxxxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxxxxxxxxx Part Procedure Section