Troubleshooting Flowcharts | Guardian Technologies 4389, 4456, 4390

AC GENERATORS

PART 2

SECTION 2.3

TROUBLESHOOTING FLOWCHARTS

GENERAL

Use 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 2.4.

The first step in using the flow charts is to correctly identify the problem. Once that has been done, locate the problem on the following pages. For best results, perform all tests in the exact sequence shown in the flow charts.

Page 2.3-1

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Guardian Technologies 4389, 4456, 4390, 4760, 4759, 4758 manual Troubleshooting Flowcharts

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 Transfer Switch / Load Center Prepackaged Transfer SwitchesSelecting a Location Grounding the Generator Prepackaged Installation Basics Part Power Source and Load Lines System Control Interconnections General Fuel Requirements Visual Inspection MetersVOM Measuring AC Voltage Measuring Resistance Measuring AC FrequencyMeasuring Current Electrical Units Ohms LAWAmpere 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 High OIL Temperature Shutdown LOW OIL Pressure ShutdownOverspeed Shutdown Overcrank Shutdown Control Panel OFF PositionManual Position Auto position SET Exercise Switch To Select Automatic OperationManual 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 ENGINE-GENERATOR Drive System Rotor AssemblyAC Generator Stator Assembly Brush Holder and BrushesOther AC Generator Components Excitation Circuit Breaker Voltage Regulator Main Line Circuit Breaker Field Boost Circuit Rotor Residual MagnetismField Boost Operation Troubleshooting Flowcharts Troubleshooting Flowcharts Part Section Section Safety ProcedureTest 1- Check Main Circuit Breaker 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 10 Test Rotor Assembly Test 12 Check and Adjust Engine GovernorTest 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 ConditionTest 14 Check Voltage Frequency Under Load Test 16 Check Engine Condition Part Type Prepackaged Transfer Switches Enclosure Limit Switches XA1 and XB1 Transfer MechanismUtility Closing Coil C1 Standby Closing Coil C2 Transfer Relay Neutral LUGManual Transfer Handle Terminal Block Fuse Holder Utility 1Terminals 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 TRNow, connect the VOM test leads across Relay Terminals 1 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 Test 33 Continuity Test of Wiring C2 Test 34 Check N1 and N2 WiringSet 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 TXCircuit 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 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 46- Check Battery Inspect Battery CablesTest Battery State of Charge Test 45- Check 15 AMP Fuse Test 47 Check Wire 56 Voltage Test Battery ConditionIf 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 armatureConditions Affecting Starter Motor Performance Checking the Pinion Tachometer Tools for Starter Performance TestMeasuring 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 FSSet the AUTO-OFF-MANUAL switch to OFF 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 Test 60- Check OIL Pressure Switch Wire Check engine crankcase oil levelWith oil level correct, try starting the engine Do the following Test 61- Check High OIL Temperature Switch Switch terminalsReplace switch if it fails the test 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 Test 66 Check AC Voltage AT Battery Charger Test 65 Check Transformer TX Voltage OutputSet a VOM to measure AC voltage 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