DIAGNOSTIC REPAIR MANUAL
AIR-COOLED
AUTOMATIC HOME STANDBY GENERATORS
Models
DIAGNOSTIC REPAIR MANUAL
TABLE OF CONTENTS
Air-cooled, Prepackaged Automatic Standby Generators
Models 04389, 04758 6 kW NG, 7 kW LP
ELECTRICAL FORMULAS
ENGINE
FUEL CONSUMPTION
STATOR WINDING RESISTANCE VALUES / ROTOR RESISTANCE
SPECIFICATIONS
SPECIFICATIONS
MOUNTING DIMENSIONS
SPECIFICATIONS
MOUNTING DIMENSIONS
MAJOR FEATURES
SPECIFICATIONS
7 kW, Single Cylinder GH-410 Engine
12 kW and 15 kW, V-twin GT-990 Engine
TABLE OF CONTENTS
PART GENERAL INFORMATION
Air-cooled, Prepackaged Automatic Standby Generators
Models 04389, 04758 6 kW NG, 7 kW LP
SECTION
GENERATOR IDENTIFICATION
PART
INTRODUCTION
PREPACKAGED INSTALLATION BASICS
THE TRANSFER SWITCH / LOAD CENTER
SELECTING A LOCATION
GROUNDING THE GENERATOR
PREPACKAGED INSTALLATION BASICS
Figure 1. Typical Prepackaged Installation
SECTION
PART
POWER SOURCE AND LOAD LINES
SYSTEM CONTROL INTERCONNECTIONS
PREPACKAGED INSTALLATION BASICS
Figure 2. Proper Fuel Installation
PREPARATION BEFORE USE
GENERAL
FUEL REQUIREMENTS
SECTION
TESTING, CLEANING AND DRYING
VISUAL INSPECTION
METERS
THE VOM
MEASURING AC FREQUENCY
MEASURING CURRENT
MEASURING RESISTANCE
TESTING, CLEANING AND DRYING
ELECTRICAL UNITS
OHMS LAW
TESTING, CLEANING AND DRYING
SECTION
TESTING, CLEANING AND DRYING
SECTION
INSULATION RESISTANCE
THE MEGOHMMETER
TESTING, CLEANING AND DRYING
2. Repeat Step 1 at Pin Location 3 Wire 66A and Stator Lead
3. Repeat Step 1 at Pin Location 7 Wire 6. and Stator Lead
Figure 3. C2 Connector Pin Location Numbers Female Side
CLEANING THE GENERATOR
ROTOR INSULATION RESISTANCE TEST
DRYING THE GENERATOR
TESTING, CLEANING AND DRYING
ENGINE-GENERATOR PROTECTIVE DEVICES
Figure 1. Engine Protective Switches on an Air-Cooled Engine
SECTION
PART
OPERATING INSTRUCTIONS
CONTROL PANEL
SECTION
PART
OPERATING INSTRUCTIONS
TO SELECT AUTOMATIC OPERATION
MANUAL TRANSFER TO STANDBY AND MANUAL STARTUP
SECTION
MANUAL SHUTDOWN AND RETRANSFER BACK TO UTILITY
SECTION
OPERATING INSTRUCTIONS
PART
AUTOMATIC OPERATING PARAMETERS
AUTOMATIC OPERATING SEQUENCES
SECTION
PART
AUTOMATIC OPERATING SEQUENCES CHART
AUTOMATIC OPERATING PARAMETERS
SECTION
PART
PART AC GENERATORS
TABLE OF CONTENTS
2.3 Troubleshooting Flow Charts 2.4 Diagnostic Tests
Air-cooled, Prepackaged Automatic Standby Generators
ROTOR ASSEMBLY
DESCRIPTION & COMPONENTS
THE AC GENERATOR
ENGINE-GENERATOR DRIVE SYSTEM
STATOR ASSEMBLY
DESCRIPTION & COMPONENTS
BRUSH HOLDER AND BRUSHES
OTHER AC GENERATOR COMPONENTS
SECTION
DESCRIPTION & COMPONENTS
PART
Figure 5. Excitation Circuit Breaker
OPERATIONAL ANALYSIS
ROTOR RESIDUAL MAGNETISM
FIELD BOOST
Figure 2. Field Boost Circuit Schematic
OPERATION
SECTION
OPERATIONAL ANALYSIS
PART
TROUBLESHOOTING FLOWCHARTS
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
SECTION
PART
TROUBLESHOOTING FLOWCHARTS
SECTION
PART
AC GENERATORS
TROUBLESHOOTING FLOWCHARTS
SECTION
PART
AC GENERATORS
TROUBLESHOOTING FLOWCHARTS
SECTION
PART
AC GENERATORS
DIAGNOSTIC TESTS
SAFETY
TEST 1- CHECK MAIN CIRCUIT BREAKER
SECTION
TEST 2- CHECK AC OUTPUT VOLTAGE
TEST 3- TEST EXCITATION CIRCUIT BREAKER
DIAGNOSTIC TESTS
SECTION
TEST 4- FIXED EXCITATION TEST ROTOR AMP DRAW TEST
DIAGNOSTIC TESTS
SECTION
PART
TEST 5 WIRE CONTINUITY
TEST 6 - CHECK FIELD BOOST
DIAGNOSTIC TESTS
SECTION
TEST 7 TESTING THE STATOR WITH A VOM
DIAGNOSTIC TESTS
SECTION
PART
TEST 8 - RESISTANCE CHECK OF ROTOR CIRCUIT
DIAGNOSTIC TESTS
SECTION
PART
TEST 9 - CHECK BRUSHES AND SLIP RINGS
DIAGNOSTIC TESTS
SECTION
PART
TEST 10 - TEST ROTOR ASSEMBLY
TEST 12 - CHECK AND ADJUST ENGINE GOVERNOR
TEST 11 - CHECK AC OUTPUT FREQUENCY
DIAGNOSTIC TESTS
DIAGNOSTIC TESTS
Figure 9. Engine Governor Adjustment Single Cylinder Engines
Figure 10. Engine Governor Adjustment V-twin Engines
Figure 11. Full Load Speed Adjust ScrewV-twin Engines
TEST 13 - CHECK AND ADJUST VOLTAGE REGULATOR
TEST 15 - CHECK FOR OVERLOAD CONDITION
TEST 14 - CHECK VOLTAGE AND FREQUENCY UNDER LOAD
TEST 16 - CHECK ENGINE CONDITION
PART V-TYPE PREPACKAGED TRANSFER SWITCHES
TABLE OF CONTENTS
Air-cooled, Prepackaged Automatic Standby Generators
Models 04389, 04758 6 kW NG, 7 kW LP
Figure 1. Exploded View of V-Type Prepackaged Transfer Switch
SECTION
DESCRIPTION & COMPONENTS
PART
TRANSFER MECHANISM
Figure 2. Load Connected to Utility Power Source
Figure 3. Load Connected to Standby Power Source
SECTION
TRANSFER RELAY
NEUTRAL LUG
MANUAL TRANSFER HANDLE
TERMINAL BLOCK
FUSE HOLDER
Figure 6. Transfer Switch Terminal Block
SECTION
PART
OPERATIONAL ANALYSIS
Figure 1. Wiring Diagram and Schematic
V-TYPE PREPACKAGED TRANSFER SWITCHES
SECTION
UTILITY SOURCE VOLTAGE AVAILABLE
Figure 2. Utility Source Power Available
SECTION
PART
OPERATIONAL ANALYSIS
UTILITY SOURCE VOLTAGE FAILURE
Figure 3. Generator Power Available, Waiting to Transfer
SECTION
TRANSFER TO STANDBY
SECTION
PART
OPERATIONAL ANALYSIS
Figure 5. Generator Powering Load
SECTION
OPERATIONAL ANALYSIS
PART
UTILITY RESTORED
Figure 6. Utility Restored, Generator Still Providing Output to Load
V-TYPE PREPACKAGED TRANSFER SWITCHES
SECTION
UTILITY RESTORED, TRANSFER SWITCH DE-ENERGIZED
Figure 7. Utility Restored, Transfer Relay De-energized
SECTION
PART
UTILITY RESTORED, RETRANSFER BACK TO UTILITY
Figure 8. Utility Restored, Retransfer Back to Utility
SECTION
PART
TRANSFER SWITCH IN UTILITY
Figure 9. Transfer Switch in UTILITY
V-TYPE PREPACKAGED TRANSFER SWITCHES
SECTION
TROUBLESHOOTING FLOW CHARTS
INTRODUCTION TO TROUBLESHOOTING
SECTION
PART
TROUBLESHOOTING FLOW CHARTS
V-TYPE PREPACKAGED TRANSFER SWITCHES
SECTION
PART
TEST 21- CHECK VOLTAGE AT TERMINAL LUGS E1, E2
DIAGNOSTIC TESTS
SECTION
PART
TEST 22 - CHECK VOLTAGE AT STANDBY CLOSING COIL C2
DIAGNOSTIC TESTS
SECTION
PART
TEST 24- CHECK MANUAL TRANSFER SWITCH OPERATION
TEST 23 - TEST TRANSFER RELAY TR
DIAGNOSTIC TESTS
SECTION
TEST 25- TEST LIMIT SWITCH XB1
DIAGNOSTIC TESTS
SECTION
PART
TEST 26 - CHECK 23 AND WIRING/CONNECTIONS
TEST 27- CHECK VOLTAGE AT TERMINAL LUGS N1, N2
DIAGNOSTIC TESTS
SECTION
UTILITY 2 TERMINALS
TEST 29- CHECK VOLTAGE AT UTILITY CLOSING COIL C1
TEST 28 - CHECK VOLTAGE AT UTILITY 1 AND
DIAGNOSTIC TESTS
TEST 31 - TEST LIMIT SWITCH XA1
TEST 30 - CHECK FUSES F1 AND F2
DIAGNOSTIC TESTS
SECTION
TEST 33 - CONTINUITY TEST OF WIRING C2
TEST 34 - CHECK N1 AND N2 WIRING
TEST 32 - CONTINUITY TEST OF WIRING C1
DIAGNOSTIC TESTS
TEST 35 - CHECK TRANSFORMER TX
DIAGNOSTIC TESTS
7. Disconnect wire N1 and wire N2 from transformer TX
SECTION
DIAGNOSTIC TESTS
SECTION
PART
Figure 6. Transformer TX
PART DC CONTROL
TABLE OF CONTENTS
Air-cooled, Prepackaged Automatic Standby Generators
Models 04389, 04758 6 kW NG, 7 kW LP
DESCRIPTION AND COMPONENTS
TERMINAL STRIP / INTERCONNECTION TERMINAL
TRANSFORMER TX
CIRCUIT BOARD
WIRE
WIRE
SECTION
PART
AUTO-OFF-MANUAL SWITCH
15 AMP FUSE
5 AMP FUSE
Figure 5. 15 Amp Fuse Figure 4. The AUTO-OFF-MANUAL Switch
SECTION
PART
DESCRIPTION AND COMPONENTS
Figure 6. Control Panel Component Identification
SECTION
OPERATIONAL ANALYSIS
PART
INTRODUCTION
SECTION
PART
OPERATIONAL ANALYSIS
DC CONTROL
INITIAL DROPOUT OF UTILITY SOURCE VOLTAGE
SECTION
OPERATIONAL ANALYSIS
PART
SECTION
PART
OPERATIONAL ANALYSIS
Page
UTILITY VOLTAGE DROPOUT AND ENGINE CRANKING
SECTION
OPERATIONAL ANALYSIS
PART
SECTION
PART
OPERATIONAL ANALYSIS
DC CONTROL
ENGINE STARTUP AND RUNNING
SECTION
OPERATIONAL ANALYSIS
PART
SECTION
PART
OPERATIONAL ANALYSIS
DC CONTROL
INITIAL TRANSFER TO THE STANDBY SOURCE
SECTION
OPERATIONAL ANALYSIS
PART
SECTION
PART
OPERATIONAL ANALYSIS
DC CONTROL
UTILITY VOLTAGE RESTORED / RE TRANSFER TO UTILITY
Figure 6. Circuit Condition - Utility Voltage Restored
SECTION
OPERATIONAL ANALYSIS
SECTION
PART
OPERATIONAL ANALYSIS
DC CONTROL
ENGINE SHUTDOWN
SECTION
OPERATIONAL ANALYSIS
PART
SECTION
PART
OPERATIONAL ANALYSIS
DC CONTROL
TROUBLESHOOTING FLOW CHARTS
SECTION
PART
DC CONTROL
TROUBLESHOOTING FLOW CHARTS
SECTION
PART
DC CONTROL
TROUBLESHOOTING FLOW CHARTS
SECTION
PART
DC CONTROL
TROUBLESHOOTING FLOW CHARTS
SECTION
PART
DC CONTROL
TROUBLESHOOTING FLOW CHARTS
SECTION
PART
DC CONTROL
TROUBLESHOOTING FLOW CHARTS
SECTION
PART
DC CONTROL
TROUBLESHOOTING FLOW CHARTS
SECTION
PART
DC CONTROL
TEST 41 - CHECK POSITION OF AUTO-OFF MANUAL SWITCH
TEST 43- TEST AUTO-OFF-MANUAL SWITCH
TEST 42 - TRY A MANUAL START
DIAGNOSTIC TESTS
DIAGNOSTIC TESTS
TEST 44- CHECK WIRE 15/15A/17/239 VOLTAGE
Figure 2. AUTO-OFF-MANUAL Switch Test Points
SECTION
TEST 46- CHECK BATTERY
TEST 45- CHECK 15 AMP FUSE
DIAGNOSTIC TESTS
SECTION
TEST 47 - CHECK WIRE 56 VOLTAGE
TEST 48- TEST STARTER CONTACTOR RELAY V-TWIN ONLY
DIAGNOSTIC TESTS
Figure 4. The Wire 56 Circuit
TEST 49- TEST STARTER CONTACTOR
DIAGNOSTIC TESTS
SECTION
PART
TEST 50- TEST STARTER MOTOR
DIAGNOSTIC TESTS
SECTION
PART
DIAGNOSTIC TESTS
SECTION
PART
Figure 10. Check Pinion Gear Operation V-Twin
DIAGNOSTIC TESTS
1. A fully charged 12 volt battery is required
SECTION
PART
TEST 51 - CHECK FUEL SUPPLY AND PRESSURE
DIAGNOSTIC TESTS
SECTION
PART
TEST 53 - CHECK CIRCUIT BOARD WIRE OUTPUT
TEST 52 - TEST FUEL SOLENOID
DIAGNOSTIC TESTS
SECTION
TEST 54 - CHECK FUEL SOLENOID
TEST 55 - CHECK FOR IGNITION SPARK
DIAGNOSTIC TESTS
SECTION
TEST 56 - CHECK SPARK PLUGS
TEST 57- CHECK ENGINE COMPRESSION
DIAGNOSTIC TESTS
SECTION
TEST 58 - CHECK SHUTDOWN WIRE
TEST 59 - CHECK AND ADJUST IGNITION MAGNETOS
DIAGNOSTIC TESTS
SECTION
DIAGNOSTIC TESTS
Figure 23. Setting Ignition Magneto Armature Air Gap
SECTION
PART
TEST 60- CHECK OIL PRESSURE SWITCH AND WIRE
DIAGNOSTIC TESTS
Figure 27. Oil Pressure Switch
SECTION
TEST 61- CHECK HIGH OIL TEMPERATURE SWITCH
DIAGNOSTIC TESTS
Figure 28. Testing the Oil Temperature Switch
SECTION
TEST 62 - CHECK AND ADJUST VALVES
TEST 63 - CHECK FUEL REGULATOR
DIAGNOSTIC TESTS
5. When full load has been achieved, connect a frequency
TEST 64 - CHECK BATTERY CHARGE OUTPUT
DIAGNOSTIC TESTS
SECTION
PART
TEST 66 - CHECK AC VOLTAGE AT BATTERY CHARGER
TEST 65 - CHECK TRANSFORMER TX VOLTAGE OUTPUT
DIAGNOSTIC TESTS
SECTION
TEST 68 - CHECK BATTERY CHARGE WINDING HARNESS
TEST 67 - CHECK BATTERY CHARGE RELAY
DIAGNOSTIC TESTS
SECTION
TEST 69 - CHECK BATTERY CHARGER WIRING
TEST 70 - CHECK ENGINE RUN WINDING
DIAGNOSTIC TESTS
SECTION
TEST 73 - TEST SET EXERCISE SWITCH
TEST 71 - CHECK N1 AND N2 VOLTAGE
AT THE CIRCUIT BOARD
TEST 72 - CHECK UTILITY SENSING VOLTAGE
TEST 74 - CHECK REMOTE START WIRING IF EQUIPPED
TEST 75 - CHECK BATTERY VOLTAGE CIRCUIT
TEST 76 - CHECK CRANKING AND RUNNING CIRCUITS
DIAGNOSTIC TESTS
TEST 77 - TEST EXERCISE FUNCTION
DIAGNOSTIC TESTS
SECTION
PART
PART OPERATIONAL TESTS
TABLE OF CONTENTS
Air-cooled, Prepackaged Automatic Standby Generators
Models 04389, 04758 6 kW NG, 7 kW LP
MANUAL TRANSFER SWITCH OPERATION
SYSTEM FUNCTIONAL TESTS
ELECTRICAL CHECKS
Figure 1. Manual Operation “V-Type” Switch
GENERATOR TESTS UNDER LOAD
SECTION
DANGER
DANGER
SETTING THE EXERCISE TIMER
CHECKING AUTOMATIC OPERATION
SECTION
SYSTEM FUNCTIONAL TESTS
PART DISASSEMBLY
TABLE OF CONTENTS
Air-cooled, Prepackaged Automatic Standby Generators
Models 04389, 04758 6 kW NG, 7 kW LP
MAJOR DISASSEMBLY
MAJOR DISASSEMBLY
10.Remove Rotor Bolt Using a 9/16 socket, remove one rotor bolt
SECTION
MAJOR DISASSEMBLY
SECTION
PART
Figure 4. Engine Adapter Supported by 2”x4” Piece of Wood
FRONT ENGINE ACCESS
MAJOR DISASSEMBLY
16.Remove Engine Using a 13mm socket, remove the
Figure 9. C1 and C2 Connectors Located on the Engine Divider Panel
PART ELECTRICAL DATA
TABLE OF CONTENTS
Air-cooled, Prepackaged Automatic Standby Generators
Models 04389, 04758 6 kW NG, 7 kW LP
WIRING DIAGRAM, 7 KW HOME STANDBY
MODEL
PART
DRAWING #0D5700-C
SCHEMATIC, 7 KW HOME STANDBY
MODEL
PART
DRAWING #0D5701-C
WIRING DIAGRAM, 12 & 15 KW HOME STANDBY
MODEL 4456-0
PART
DRAWING #0C7830-C
SCHEMATIC, 12 & 15 KW HOME STANDBY
MODEL 4456-0
PART
DRAWING #0C7836-C
WIRING DIAGRAM, 7 KW HOME STANDBY
MODEL
PART
DRAWING #0D9013-C 1 OF
WIRING DIAGRAM, 7 KW HOME STANDBY
MODEL
PART
DRAWING #0D9013-C 2 OF
SCHEMATIC, 7 KW HOME STANDBY
MODEL
PART
DRAWING #0D9014-B 1 OF
SCHEMATIC, 7 KW HOME STANDBY
MODEL
PART
DRAWING #0D9014-B 2 OF
MODEL 4456-1
WIRING DIAGRAM, 12 & 15 KW HOME STANDBY
PART
DRAWING #0D8500-B 1 OF
WIRING DIAGRAM, 12 & 15 KW HOME STANDBY
MODEL 4456-1
PART
DRAWING #0D8500-B 2 OF
SCHEMATIC, 12 & 15 KW HOME STANDBY
MODEL 4456-1
PART
DRAWING #0D8501-B 1 OF
SCHEMATIC, 12 & 15 KW HOME STANDBY
MODEL 4456-1
PART
DRAWING #0D8501-B 2 OF
ELECTRICAL DATA
PART
Page
PART
ELECTRICAL DATA
ELECTRICAL DATA
PART
Page
Page
P/N OE3586/Printed in the USA/1.03/Rev
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1. Repair engine, or replace defective parts, or adjust as necessary
2. If no engine problems are found, go to Test
SECTION
SECTION
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PART
3.4 provides detailed instructions for performance of each test
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SECTION
PART
SECTION
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PART
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