Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4456 Part Disassembly, Air-cooled, Prepackaged Automatic Standby Generators

Models: 4758 4759 4760 4389 4390 4456

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PART 6

DISASSEMBLY

Air-cooled, Prepackaged Automatic Standby Generators

Models: 04389, 04758 (6 kW NG, 7 kW LP)

04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP)

TABLE OF CONTENTS

PART

TITLE

6.1Major Disassembly

6.2Torque Specifications

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Contents

AUTOMATIC HOME STANDBY GENERATORS DIAGNOSTIC REPAIR MANUALAIR-COOLED ModelsAir-cooled, Prepackaged Automatic Standby Generators DIAGNOSTIC REPAIR MANUALTABLE OF CONTENTS Models 04389, 04758 6 kW NG, 7 kW LPELECTRICAL FORMULAS STATOR WINDING RESISTANCE VALUES / ROTOR RESISTANCE ENGINEFUEL CONSUMPTION SPECIFICATIONSSPECIFICATIONS MOUNTING DIMENSIONSSPECIFICATIONS MOUNTING DIMENSIONS7 kW, Single Cylinder GH-410 Engine MAJOR FEATURESSPECIFICATIONS 12 kW and 15 kW, V-twin GT-990 EngineAir-cooled, Prepackaged Automatic Standby Generators TABLE OF CONTENTSPART GENERAL INFORMATION Models 04389, 04758 6 kW NG, 7 kW LPPART SECTIONGENERATOR IDENTIFICATION INTRODUCTIONSELECTING A LOCATION PREPACKAGED INSTALLATION BASICSTHE TRANSFER SWITCH / LOAD CENTER GROUNDING THE GENERATORSECTION PREPACKAGED INSTALLATION BASICSFigure 1. Typical Prepackaged Installation PARTPREPACKAGED INSTALLATION BASICS POWER SOURCE AND LOAD LINESSYSTEM CONTROL INTERCONNECTIONS Figure 2. Proper Fuel InstallationFUEL REQUIREMENTS PREPARATION BEFORE USEGENERAL SECTIONMETERS TESTING, CLEANING AND DRYINGVISUAL INSPECTION THE VOMMEASURING RESISTANCE MEASURING AC FREQUENCYMEASURING CURRENT TESTING, CLEANING AND DRYINGTESTING, CLEANING AND DRYING ELECTRICAL UNITSOHMS LAW SECTIONINSULATION RESISTANCE TESTING, CLEANING AND DRYINGSECTION THE MEGOHMMETER3. Repeat Step 1 at Pin Location 7 Wire 6. and Stator Lead TESTING, CLEANING AND DRYING2. Repeat Step 1 at Pin Location 3 Wire 66A and Stator Lead Figure 3. C2 Connector Pin Location Numbers Female SideDRYING THE GENERATOR CLEANING THE GENERATORROTOR INSULATION RESISTANCE TEST TESTING, CLEANING AND DRYINGSECTION ENGINE-GENERATOR PROTECTIVE DEVICESFigure 1. Engine Protective Switches on an Air-Cooled Engine PARTSECTION OPERATING INSTRUCTIONSCONTROL PANEL PARTMANUAL TRANSFER TO STANDBY AND MANUAL STARTUP OPERATING INSTRUCTIONSTO SELECT AUTOMATIC OPERATION SECTIONOPERATING INSTRUCTIONS MANUAL SHUTDOWN AND RETRANSFER BACK TO UTILITYSECTION PARTSECTION AUTOMATIC OPERATING PARAMETERSAUTOMATIC OPERATING SEQUENCES PARTSECTION AUTOMATIC OPERATING SEQUENCES CHARTAUTOMATIC OPERATING PARAMETERS PART2.3 Troubleshooting Flow Charts 2.4 Diagnostic Tests PART AC GENERATORSTABLE OF CONTENTS Air-cooled, Prepackaged Automatic Standby GeneratorsTHE AC GENERATOR ROTOR ASSEMBLYDESCRIPTION & COMPONENTS ENGINE-GENERATOR DRIVE SYSTEMBRUSH HOLDER AND BRUSHES STATOR ASSEMBLYDESCRIPTION & COMPONENTS OTHER AC GENERATOR COMPONENTSPART SECTIONDESCRIPTION & COMPONENTS Figure 5. Excitation Circuit BreakerFIELD BOOST OPERATIONAL ANALYSISROTOR RESIDUAL MAGNETISM Figure 2. Field Boost Circuit SchematicOPERATIONAL ANALYSIS OPERATIONSECTION PARTSECTION TROUBLESHOOTING FLOWCHARTSUse the Flow Charts in conjunction with the detailed instructions in Section 2.4. Test numbers used in the flow charts correspond to the numbered tests in Section PARTPART TROUBLESHOOTING FLOWCHARTSSECTION AC GENERATORSPART TROUBLESHOOTING FLOWCHARTSSECTION AC GENERATORSPART TROUBLESHOOTING FLOWCHARTSSECTION AC GENERATORSTEST 1- CHECK MAIN CIRCUIT BREAKER DIAGNOSTIC TESTSSAFETY SECTIONDIAGNOSTIC TESTS TEST 2- CHECK AC OUTPUT VOLTAGETEST 3- TEST EXCITATION CIRCUIT BREAKER SECTIONSECTION TEST 4- FIXED EXCITATION TEST ROTOR AMP DRAW TESTDIAGNOSTIC TESTS PARTDIAGNOSTIC TESTS TEST 5 WIRE CONTINUITYTEST 6 - CHECK FIELD BOOST SECTIONSECTION TEST 7 TESTING THE STATOR WITH A VOMDIAGNOSTIC TESTS PARTSECTION TEST 8 - RESISTANCE CHECK OF ROTOR CIRCUITDIAGNOSTIC TESTS PARTSECTION TEST 9 - CHECK BRUSHES AND SLIP RINGSDIAGNOSTIC TESTS PARTTEST 11 - CHECK AC OUTPUT FREQUENCY TEST 10 - TEST ROTOR ASSEMBLYTEST 12 - CHECK AND ADJUST ENGINE GOVERNOR DIAGNOSTIC TESTSFigure 10. Engine Governor Adjustment V-twin Engines DIAGNOSTIC TESTSFigure 9. Engine Governor Adjustment Single Cylinder Engines Figure 11. Full Load Speed Adjust ScrewV-twin EnginesTEST 14 - CHECK VOLTAGE AND FREQUENCY UNDER LOAD TEST 13 - CHECK AND ADJUST VOLTAGE REGULATORTEST 15 - CHECK FOR OVERLOAD CONDITION TEST 16 - CHECK ENGINE CONDITIONAir-cooled, Prepackaged Automatic Standby Generators PART V-TYPE PREPACKAGED TRANSFER SWITCHESTABLE OF CONTENTS Models 04389, 04758 6 kW NG, 7 kW LPDESCRIPTION & COMPONENTS Figure 1. Exploded View of V-Type Prepackaged Transfer SwitchSECTION PARTFigure 3. Load Connected to Standby Power Source TRANSFER MECHANISMFigure 2. Load Connected to Utility Power Source SECTIONMANUAL TRANSFER HANDLE TRANSFER RELAYNEUTRAL LUG TERMINAL BLOCKSECTION FUSE HOLDERFigure 6. Transfer Switch Terminal Block PARTV-TYPE PREPACKAGED TRANSFER SWITCHES OPERATIONAL ANALYSISFigure 1. Wiring Diagram and Schematic SECTIONSECTION UTILITY SOURCE VOLTAGE AVAILABLEFigure 2. Utility Source Power Available PARTFigure 3. Generator Power Available, Waiting to Transfer OPERATIONAL ANALYSISUTILITY SOURCE VOLTAGE FAILURE SECTIONPART TRANSFER TO STANDBYSECTION OPERATIONAL ANALYSISOPERATIONAL ANALYSIS Figure 5. Generator Powering LoadSECTION PARTV-TYPE PREPACKAGED TRANSFER SWITCHES UTILITY RESTOREDFigure 6. Utility Restored, Generator Still Providing Output to Load SECTIONSECTION UTILITY RESTORED, TRANSFER SWITCH DE-ENERGIZEDFigure 7. Utility Restored, Transfer Relay De-energized PARTSECTION UTILITY RESTORED, RETRANSFER BACK TO UTILITYFigure 8. Utility Restored, Retransfer Back to Utility PARTV-TYPE PREPACKAGED TRANSFER SWITCHES TRANSFER SWITCH IN UTILITYFigure 9. Transfer Switch in UTILITY SECTIONSECTION TROUBLESHOOTING FLOW CHARTSINTRODUCTION TO TROUBLESHOOTING PARTSECTION TROUBLESHOOTING FLOW CHARTSV-TYPE PREPACKAGED TRANSFER SWITCHES PARTSECTION TEST 21- CHECK VOLTAGE AT TERMINAL LUGS E1, E2DIAGNOSTIC TESTS PARTSECTION TEST 22 - CHECK VOLTAGE AT STANDBY CLOSING COIL C2DIAGNOSTIC TESTS PARTDIAGNOSTIC TESTS TEST 24- CHECK MANUAL TRANSFER SWITCH OPERATIONTEST 23 - TEST TRANSFER RELAY TR SECTIONSECTION TEST 25- TEST LIMIT SWITCH XB1DIAGNOSTIC TESTS PARTDIAGNOSTIC TESTS TEST 26 - CHECK 23 AND WIRING/CONNECTIONSTEST 27- CHECK VOLTAGE AT TERMINAL LUGS N1, N2 SECTIONTEST 28 - CHECK VOLTAGE AT UTILITY 1 AND UTILITY 2 TERMINALSTEST 29- CHECK VOLTAGE AT UTILITY CLOSING COIL C1 DIAGNOSTIC TESTSDIAGNOSTIC TESTS TEST 31 - TEST LIMIT SWITCH XA1TEST 30 - CHECK FUSES F1 AND F2 SECTIONTEST 32 - CONTINUITY TEST OF WIRING C1 TEST 33 - CONTINUITY TEST OF WIRING C2TEST 34 - CHECK N1 AND N2 WIRING DIAGNOSTIC TESTS7. Disconnect wire N1 and wire N2 from transformer TX TEST 35 - CHECK TRANSFORMER TXDIAGNOSTIC TESTS SECTIONPART DIAGNOSTIC TESTSSECTION Figure 6. Transformer TXAir-cooled, Prepackaged Automatic Standby Generators PART DC CONTROLTABLE OF CONTENTS Models 04389, 04758 6 kW NG, 7 kW LPTRANSFORMER TX DESCRIPTION AND COMPONENTSTERMINAL STRIP / INTERCONNECTION TERMINAL CIRCUIT BOARDSECTION WIREWIRE PART5 AMP FUSE AUTO-OFF-MANUAL SWITCH15 AMP FUSE Figure 5. 15 Amp Fuse Figure 4. The AUTO-OFF-MANUAL SwitchDESCRIPTION AND COMPONENTS SECTIONPART Figure 6. Control Panel Component IdentificationPART SECTIONOPERATIONAL ANALYSIS INTRODUCTIONOPERATIONAL ANALYSIS SECTIONPART DC CONTROLOPERATIONAL ANALYSIS INITIAL DROPOUT OF UTILITY SOURCE VOLTAGESECTION PARTOPERATIONAL ANALYSIS SECTIONPART PageOPERATIONAL ANALYSIS UTILITY VOLTAGE DROPOUT AND ENGINE CRANKINGSECTION PARTOPERATIONAL ANALYSIS SECTIONPART DC CONTROLOPERATIONAL ANALYSIS ENGINE STARTUP AND RUNNINGSECTION PARTOPERATIONAL ANALYSIS SECTIONPART DC CONTROLOPERATIONAL ANALYSIS INITIAL TRANSFER TO THE STANDBY SOURCESECTION PARTOPERATIONAL ANALYSIS SECTIONPART DC CONTROLSECTION UTILITY VOLTAGE RESTORED / RE TRANSFER TO UTILITYFigure 6. Circuit Condition - Utility Voltage Restored OPERATIONAL ANALYSISOPERATIONAL ANALYSIS SECTIONPART DC CONTROLOPERATIONAL ANALYSIS ENGINE SHUTDOWNSECTION PARTOPERATIONAL ANALYSIS SECTIONPART DC CONTROLPART TROUBLESHOOTING FLOW CHARTSSECTION DC CONTROLPART TROUBLESHOOTING FLOW CHARTSSECTION DC CONTROLPART TROUBLESHOOTING FLOW CHARTSSECTION DC CONTROLPART TROUBLESHOOTING FLOW CHARTSSECTION DC CONTROLPART TROUBLESHOOTING FLOW CHARTSSECTION DC CONTROLPART TROUBLESHOOTING FLOW CHARTSSECTION DC CONTROLPART TROUBLESHOOTING FLOW CHARTSSECTION DC CONTROLTEST 42 - TRY A MANUAL START TEST 41 - CHECK POSITION OF AUTO-OFF MANUAL SWITCHTEST 43- TEST AUTO-OFF-MANUAL SWITCH DIAGNOSTIC TESTSFigure 2. AUTO-OFF-MANUAL Switch Test Points DIAGNOSTIC TESTSTEST 44- CHECK WIRE 15/15A/17/239 VOLTAGE SECTIONDIAGNOSTIC TESTS TEST 46- CHECK BATTERYTEST 45- CHECK 15 AMP FUSE SECTIONDIAGNOSTIC TESTS TEST 47 - CHECK WIRE 56 VOLTAGETEST 48- TEST STARTER CONTACTOR RELAY V-TWIN ONLY Figure 4. The Wire 56 CircuitSECTION TEST 49- TEST STARTER CONTACTORDIAGNOSTIC TESTS PARTSECTION TEST 50- TEST STARTER MOTORDIAGNOSTIC TESTS PARTPART DIAGNOSTIC TESTSSECTION Figure 10. Check Pinion Gear Operation V-TwinSECTION DIAGNOSTIC TESTS1. A fully charged 12 volt battery is required PARTSECTION TEST 51 - CHECK FUEL SUPPLY AND PRESSUREDIAGNOSTIC TESTS PARTDIAGNOSTIC TESTS TEST 53 - CHECK CIRCUIT BOARD WIRE OUTPUTTEST 52 - TEST FUEL SOLENOID SECTIONDIAGNOSTIC TESTS TEST 54 - CHECK FUEL SOLENOIDTEST 55 - CHECK FOR IGNITION SPARK SECTIONDIAGNOSTIC TESTS TEST 56 - CHECK SPARK PLUGSTEST 57- CHECK ENGINE COMPRESSION SECTIONDIAGNOSTIC TESTS TEST 58 - CHECK SHUTDOWN WIRETEST 59 - CHECK AND ADJUST IGNITION MAGNETOS SECTIONSECTION DIAGNOSTIC TESTSFigure 23. Setting Ignition Magneto Armature Air Gap PARTFigure 27. Oil Pressure Switch TEST 60- CHECK OIL PRESSURE SWITCH AND WIREDIAGNOSTIC TESTS SECTIONFigure 28. Testing the Oil Temperature Switch TEST 61- CHECK HIGH OIL TEMPERATURE SWITCHDIAGNOSTIC TESTS SECTIONDIAGNOSTIC TESTS TEST 62 - CHECK AND ADJUST VALVESTEST 63 - CHECK FUEL REGULATOR 5. When full load has been achieved, connect a frequencySECTION TEST 64 - CHECK BATTERY CHARGE OUTPUTDIAGNOSTIC TESTS PARTDIAGNOSTIC TESTS TEST 66 - CHECK AC VOLTAGE AT BATTERY CHARGERTEST 65 - CHECK TRANSFORMER TX VOLTAGE OUTPUT SECTIONDIAGNOSTIC TESTS TEST 68 - CHECK BATTERY CHARGE WINDING HARNESSTEST 67 - CHECK BATTERY CHARGE RELAY SECTIONDIAGNOSTIC TESTS TEST 69 - CHECK BATTERY CHARGER WIRINGTEST 70 - CHECK ENGINE RUN WINDING SECTIONAT THE CIRCUIT BOARD TEST 73 - TEST SET EXERCISE SWITCHTEST 71 - CHECK N1 AND N2 VOLTAGE TEST 72 - CHECK UTILITY SENSING VOLTAGETEST 76 - CHECK CRANKING AND RUNNING CIRCUITS TEST 74 - CHECK REMOTE START WIRING IF EQUIPPEDTEST 75 - CHECK BATTERY VOLTAGE CIRCUIT DIAGNOSTIC TESTSSECTION TEST 77 - TEST EXERCISE FUNCTIONDIAGNOSTIC TESTS PARTAir-cooled, Prepackaged Automatic Standby Generators PART OPERATIONAL TESTSTABLE OF CONTENTS Models 04389, 04758 6 kW NG, 7 kW LPELECTRICAL CHECKS MANUAL TRANSFER SWITCH OPERATIONSYSTEM FUNCTIONAL TESTS Figure 1. Manual Operation “V-Type” SwitchDANGER GENERATOR TESTS UNDER LOADSECTION DANGERSECTION SETTING THE EXERCISE TIMERCHECKING AUTOMATIC OPERATION SYSTEM FUNCTIONAL TESTSAir-cooled, Prepackaged Automatic Standby Generators PART DISASSEMBLYTABLE OF CONTENTS Models 04389, 04758 6 kW NG, 7 kW LP10.Remove Rotor Bolt Using a 9/16 socket, remove one rotor bolt MAJOR DISASSEMBLYMAJOR DISASSEMBLY SECTIONPART MAJOR DISASSEMBLYSECTION Figure 4. Engine Adapter Supported by 2”x4” Piece of Wood16.Remove Engine Using a 13mm socket, remove the FRONT ENGINE ACCESSMAJOR DISASSEMBLY Figure 9. C1 and C2 Connectors Located on the Engine Divider PanelAir-cooled, Prepackaged Automatic Standby Generators PART ELECTRICAL DATATABLE OF CONTENTS Models 04389, 04758 6 kW NG, 7 kW LPPART WIRING DIAGRAM, 7 KW HOME STANDBYMODEL DRAWING #0D5700-CPART SCHEMATIC, 7 KW HOME STANDBYMODEL DRAWING #0D5701-CPART WIRING DIAGRAM, 12 & 15 KW HOME STANDBYMODEL 4456-0 DRAWING #0C7830-CPART SCHEMATIC, 12 & 15 KW HOME STANDBYMODEL 4456-0 DRAWING #0C7836-CPART WIRING DIAGRAM, 7 KW HOME STANDBYMODEL DRAWING #0D9013-C 1 OFPART WIRING DIAGRAM, 7 KW HOME STANDBYMODEL DRAWING #0D9013-C 2 OFPART SCHEMATIC, 7 KW HOME STANDBYMODEL DRAWING #0D9014-B 1 OFPART SCHEMATIC, 7 KW HOME STANDBYMODEL DRAWING #0D9014-B 2 OFPART MODEL 4456-1WIRING DIAGRAM, 12 & 15 KW HOME STANDBY DRAWING #0D8500-B 1 OFPART WIRING DIAGRAM, 12 & 15 KW HOME STANDBYMODEL 4456-1 DRAWING #0D8500-B 2 OFPART SCHEMATIC, 12 & 15 KW HOME STANDBYMODEL 4456-1 DRAWING #0D8501-B 1 OFPART SCHEMATIC, 12 & 15 KW HOME STANDBYMODEL 4456-1 DRAWING #0D8501-B 2 OFPART PageELECTRICAL DATA PART ELECTRICAL DATAPART PageELECTRICAL DATA Page P/N OE3586/Printed in the USA/1.03/Rev 2. If no engine problems are found, go to Test XXXXXXXXXXXXXXXXXXXXXXXXXXX1. Repair engine, or replace defective parts, or adjust as necessary SECTIONPART SECTIONXXXXXXXXXXXXXXXXXXXXXXXXXXX 3.4 provides detailed instructions for performance of each testSECTION PARTXXXXXXXXXXXXXXXXXXXXXXXXXXX PART SECTIONXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX