Diagnostic Repair Manual | Guardian Technologies 4389, 4456, 4390

DIAGNOSTIC

REPAIR MANUAL

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
	Specifications
1	General Information
2	AC Generators
3	V-Type Prepackaged Transfer Switches
4	DC Control
5	Operational Tests and Adjustments
6	Disassembly
7	Electrical Data

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

Contents

Diagnostic Repair Manual Diagnostic Repair Manual Electrical Formulas Stator Winding Resistance Values / Rotor Resistance EngineFuel Consumption Mounting Dimensions Specifications Major Features Part General Information Serial Number IntroductionItem Number Selecting a Location Transfer Switch / Load CenterPrepackaged Transfer Switches Grounding the Generator Prepackaged Installation Basics Part Power Source and Load Lines System Control Interconnections General Fuel Requirements VOM Visual InspectionMeters Measuring AC Voltage Measuring Resistance Measuring AC FrequencyMeasuring Current Ampere Electrical UnitsOhms LAW Volt Stator Insulation Resistance Test Insulation ResistanceMegohmmeter Testing ALL Stator Windings to Ground Test Between Windings Drying the Generator Cleaning the GeneratorRotor Insulation Resistance Test Overspeed Shutdown High OIL Temperature ShutdownLOW OIL Pressure Shutdown Overcrank Shutdown Manual Position Control PanelOFF Position Auto position Manual Transfer to Standby Manual Startup SET Exercise SwitchTo Select Automatic Operation 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 ENGINE-GENERATOR Drive System Rotor AssemblyAC Generator Other AC Generator Components Stator AssemblyBrush Holder and Brushes Excitation Circuit Breaker Voltage Regulator Main Line Circuit Breaker Field Boost Circuit Rotor Residual MagnetismField Boost Operation Troubleshooting Flowcharts Troubleshooting Flowcharts Part Section Section Test 1- Check Main Circuit Breaker SafetyProcedure Discussion If a high voltage is indicated, go on to Test Test 2- Check AC Output VoltageTest 3- Test Excitation Circuit Breaker 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 If continuity was measured in steps 5 and 6 proceed to step Remove wire 4 from the voltage regulatorTest 9 Check Brushes Slip Rings Test 11 Check AC Output Frequency Test 10 Test Rotor AssemblyTest 12 Check and Adjust Engine Governor Start the engine, let it stabilize and warm up at no-load Procedure 7KW Units Loosen the governor clamp bolt Figure Test 14 Check Voltage Frequency Under Load Test 13 Check and Adjust Voltage RegulatorTest 15 Check for Overload Condition Test 16 Check Engine Condition Part Type Prepackaged Transfer Switches Enclosure Utility Closing Coil C1 Limit Switches XA1 and XB1Transfer Mechanism Standby Closing Coil C2 Manual Transfer Handle Transfer RelayNeutral LUG Terminal Block Terminals 23 Fuse HolderUtility 1 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 Now, connect the VOM test leads across Relay Terminals 1 Test 24- Check Manual Transfer Switch OperationTest 23 Test Transfer Relay TR Continuity Results Test 25- Test Limit Switch XB1 Test 27- Check Voltage AT Terminal Lugs N1, N2 WIRING/CONNECTIONSPROCEDURE/RESULTS 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 Set the AUTO-OFF-MANUAL switch to the OFF position Test 33 Continuity Test of Wiring C2Test 34 Check N1 and N2 Wiring See Test 32, Step Test 35 Check Transformer TX Transformer TX Part DC Control Circuit Board Terminal Strip / InterconnectionTransformer TX 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 42 TRY a Manual Start Test 41 Check Position of AUTO-OFF Manual SwitchTest 43- Test AUTO-OFF-MANUAL Switch Replace AUTO-OFF-MANUAL switch, if defective Set a VOM to measure DC voltage Test Battery State of Charge Test 46- Check BatteryInspect Battery Cables Test 45- Check 15 AMP Fuse If battery voltage is not indicated in , go to Test Test 47 Check Wire 56 VoltageTest Battery Condition Test 48- Test Starter Contactor Relay V-TWIN only Test 49- Test Starter Contactor Starter Contactor Relay Conditions Affecting Starter Motor Performance Test 50- Test Starter MotorShorted, open or grounded armature Checking the Pinion Measuring Current TachometerTools for Starter Performance Test Test Bracket Testing Starter Motor Remove Starter Motor Testing Starter Motor Performance Test 51 Check Fuel Supply Pressure Set the AUTO-OFF-MANUAL switch to OFF Test 53 Check Circuit Board Wire OutputDisconnect Wire 14 at the Fuel Solenoid FS Test 52 Test Fuel Solenoid Test 54 Check Fuel Solenoid Test 55 Check for Ignition Spark If sparking occurs but engine still wont start, go to Test Test 56 Check Spark PlugsTest 57- Check Engine Compression If ignition spark still has not occurred, proceed to Test Test 58 Check Shutdown WireTest 59 Check and Adjust Ignition Magnetos Setting Ignition Magneto Armature Air Gap With oil level correct, try starting the engine Test 60- Check OIL Pressure Switch WireCheck engine crankcase oil level Do the following Replace switch if it fails the test Test 61- Check High OIL Temperature SwitchSwitch terminals Remove the High Oil Temperature Switch Test 63 Check Fuel Regulator Test 62 Check and Adjust ValvesProcedure Intake and Exhaust Test 64 Check Battery Charge Output Set a VOM to measure AC voltage Test 66 Check AC Voltage AT Battery ChargerTest 65 Check Transformer TX Voltage Output If voltage was not measured in , go to Test Test 68 Check Battery Charge Winding Harness BCR Set VOM to measure frequency 63 HZ should be measured Test 69 Check Battery Charger WiringTest 70 Check Engine RUN Winding AT the Circuit Board Test 73 Test SET Exercise SwitchTest 71 Check N1 and N2 Voltage Test 76 Check Cranking and Running Circuits Test 74 Check Remote Start Wiring If EquippedTest 75 Check Battery Voltage Circuit Test 77 Test Exercise Function Continuity Part Operational Tests Electrical Checks Manual Transfer Switch OperationType Transfer Switches Generator Tests Under Load Checking Automatic Operation Setting the Exercise TimerVerify that the AUTO-OFF-MANUAL switch is set to Auto Part Disassembly STATOR/ROTOR/ENGINE Removal Major DisassemblyRemove door Major Disassembly Reverse the previous steps to re-assemble Front Engine AccessFollow Stator/Rotor/Engine removal procedures, Steps 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