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