Introduction, Item Number | Guardian Technologies 4760, 4456, 4390

SECTION 1.1

GENERATOR IDENTIFICATION

PART 1

GENERAL INFORMATION

INTRODUCTION

This Diagnostic Repair Manual has been prepared especially for the purpose of familiarizing service personnel with the testing, troubleshooting and repair of air-cooled, prepackaged automatic standby generators. Every effort has been expended to ensure that information and instructions in the manual are both accurate and current. However, Generac reserves the right to change, alter or otherwise improve the product at any time without prior notification.

The manual has been divided into ten PARTS. Each PART has been divided into SECTIONS. Each SECTION consists of two or more SUBSECTIONS.

It is not our intent to provide detailed disassembly and reassemble instructions in this manual. It is our intent to (a) provide the service technician with an understanding of how the various assemblies and systems work, (b) assist the technician in finding the cause of malfunctions, and (c) effect the expeditious repair of the equipment.

ITEM NUMBER:

Many home standby generators are manufactured to the unique specifications of the buyer. The Model Number identifies the specific generator set and its unique design specifications.

SERIAL NUMBER:

Used for warranty tracking purposes.

Figure 1. A Typical Data Plate

Page 1.1-1

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Guardian Technologies 4760, 4456, 4390, 4389, 4759, 4758 manual Introduction, Item Number, Serial Number

Contents

Diagnostic Repair Manual Diagnostic Repair Manual Electrical Formulas Engine Fuel ConsumptionStator Winding Resistance Values / Rotor Resistance Mounting Dimensions Specifications Major Features Part General Information Introduction Item NumberSerial Number Prepackaged Transfer Switches Transfer Switch / Load CenterSelecting a Location Grounding the Generator Prepackaged Installation Basics Part System Control Interconnections Power Source and Load Lines Fuel Requirements General Meters Visual InspectionVOM Measuring AC Voltage Measuring AC Frequency Measuring CurrentMeasuring Resistance Ohms LAW Electrical UnitsAmpere Volt Insulation Resistance MegohmmeterStator Insulation Resistance Test Test Between Windings Testing ALL Stator Windings to Ground Cleaning the Generator Rotor Insulation Resistance TestDrying the Generator LOW OIL Pressure Shutdown High OIL Temperature ShutdownOverspeed Shutdown Overcrank Shutdown OFF Position Control PanelManual Position Auto position To Select Automatic Operation SET Exercise SwitchManual Transfer to Standby Manual Startup Protection Systems Manual Shutdown and Retransfer Back to Utility Automatic Operating Sequences Automatic Operating Parameters SEQ. Condition Action SENSOR, Timer or Other Part AC Generators Rotor Assembly AC GeneratorENGINE-GENERATOR Drive System Brush Holder and Brushes Stator AssemblyOther AC Generator Components Excitation Circuit Breaker Main Line Circuit Breaker Voltage Regulator Rotor Residual Magnetism Field BoostField Boost Circuit Operation Troubleshooting Flowcharts Troubleshooting Flowcharts Part Section Section Procedure SafetyTest 1- Check Main Circuit Breaker Discussion Test 2- Check AC Output Voltage Test 3- Test Excitation Circuit BreakerIf a high voltage is indicated, go on to Test Set VOM to AC volts Test 4- Fixed Excitation Test Rotor AMP Draw Test Test 6 Check Field Boost Test 5 Wire Continuity Test 7 Testing the Stator with a VOM Set VOM to the Rx1 scale Test 8 Resistance Check Rotor Circuit Remove wire 4 from the voltage regulator Test 9 Check Brushes Slip RingsIf continuity was measured in steps 5 and 6 proceed to step Test 12 Check and Adjust Engine Governor Test 10 Test Rotor AssemblyTest 11 Check AC Output Frequency Start the engine, let it stabilize and warm up at no-load Loosen the governor clamp bolt Figure Procedure 7KW Units Test 15 Check for Overload Condition Test 13 Check and Adjust Voltage RegulatorTest 14 Check Voltage Frequency Under Load Test 16 Check Engine Condition Part Type Prepackaged Transfer Switches Enclosure Transfer Mechanism Limit Switches XA1 and XB1Utility Closing Coil C1 Standby Closing Coil C2 Neutral LUG Transfer RelayManual Transfer Handle Terminal Block Utility 1 Fuse HolderTerminals 23 Fuses F1, F2 Operational Analysis Wiring Diagram and Schematic Utility Source Voltage Available Utility Source Power Available Utility Source Voltage Failure Generator Power Available, Waiting to Transfer Transfer Action to Standby Position Transfer to Standby Generator Powering Load Utility Restored, Generator Still Providing Output to Load Utility Restored Utility Restored, Transfer Relay De-energized Utility RESTORED, Transfer Switch DE-ENERGIZED Utility RESTORED, Retransfer Back to Utility Transfer Switch in Utility Transfer Switch in Utility Introduction to Troubleshooting Troubleshooting Flow Charts Part If the generator has been shut down, proceed as follows Test 21- Check Voltage AT Terminal Lugs E1, E2 Test 22 Check Voltage AT Standby Closing Coil C2 Test 23 Test Transfer Relay TR Test 24- Check Manual Transfer Switch OperationNow, connect the VOM test leads across Relay Terminals 1 Continuity Results Test 25- Test Limit Switch XB1 WIRING/CONNECTIONS PROCEDURE/RESULTSTest 27- Check Voltage AT Terminal Lugs N1, N2 Test 29- Check Voltage AT Utility Closing Coil C1 Utility 2 Terminals Test 30 Check Fuses F1 and F2 Test 31 Test Limit Switch XA1 Test 34 Check N1 and N2 Wiring Test 33 Continuity Test of Wiring C2Set the AUTO-OFF-MANUAL switch to the OFF position See Test 32, Step Test 35 Check Transformer TX Transformer TX Part DC Control Transformer TX Terminal Strip / InterconnectionCircuit Board Utility 1 and Utility Description and Components AMP Fuse AUTO-OFF-MANUAL Switch Control Panel Component Identification Circuit Condition Utility Source Voltage Available Operational Analysis Circuit Condition Initial Dropout of Utility Source Voltage Initial Dropout Utility Source Voltage Section Utility Voltage Dropout Engine Cranking Section Circuit Condition Engine Startup and Running Engine Startup and Running Section Initial Transfer to Standby Source Section Circuit Condition Utility Voltage Restored Utility Voltage Restored / RE Transfer to Utility Section Circuit Condition Retransfer to Utility and Engine Shutdown 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 SwitchTest 42 TRY a Manual Start Set a VOM to measure DC voltage Replace AUTO-OFF-MANUAL switch, if defective Inspect Battery Cables Test 46- Check BatteryTest Battery State of Charge Test 45- Check 15 AMP Fuse Test Battery Condition Test 47 Check Wire 56 VoltageIf battery voltage is not indicated in , go to Test Test 48- Test Starter Contactor Relay V-TWIN only Starter Contactor Relay Test 49- Test Starter Contactor Shorted, open or grounded armature Test 50- Test Starter MotorConditions Affecting Starter Motor Performance Checking the Pinion Tools for Starter Performance Test TachometerMeasuring Current Test Bracket Remove Starter Motor Testing Starter Motor Test 51 Check Fuel Supply Pressure Testing Starter Motor Performance Disconnect Wire 14 at the Fuel Solenoid FS Test 53 Check Circuit Board Wire OutputSet the AUTO-OFF-MANUAL switch to OFF Test 52 Test Fuel Solenoid Test 55 Check for Ignition Spark Test 54 Check Fuel Solenoid Test 56 Check Spark Plugs Test 57- Check Engine CompressionIf sparking occurs but engine still wont start, go to Test Test 58 Check Shutdown Wire Test 59 Check and Adjust Ignition MagnetosIf ignition spark still has not occurred, proceed to Test Setting Ignition Magneto Armature Air Gap Check engine crankcase oil level Test 60- Check OIL Pressure Switch WireWith oil level correct, try starting the engine Do the following Switch terminals Test 61- Check High OIL Temperature SwitchReplace switch if it fails the test Remove the High Oil Temperature Switch Test 62 Check and Adjust Valves Procedure Intake and ExhaustTest 63 Check Fuel Regulator Test 64 Check Battery Charge Output Test 65 Check Transformer TX Voltage Output Test 66 Check AC Voltage AT Battery ChargerSet a VOM to measure AC voltage If voltage was not measured in , go to Test BCR Test 68 Check Battery Charge Winding Harness Test 69 Check Battery Charger Wiring Test 70 Check Engine RUN WindingSet VOM to measure frequency 63 HZ should be measured Test 73 Test SET Exercise Switch Test 71 Check N1 and N2 VoltageAT the Circuit Board Test 74 Check Remote Start Wiring If Equipped Test 75 Check Battery Voltage CircuitTest 76 Check Cranking and Running Circuits Continuity Test 77 Test Exercise Function Part Operational Tests Manual Transfer Switch Operation Type Transfer SwitchesElectrical Checks Generator Tests Under Load Setting the Exercise Timer Verify that the AUTO-OFF-MANUAL switch is set to AutoChecking Automatic Operation Part Disassembly Major Disassembly Remove doorSTATOR/ROTOR/ENGINE Removal Major Disassembly Front Engine Access Follow Stator/Rotor/Engine removal procedures, StepsReverse 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 Xxxxxxxxxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxxxxxxxxx Part Procedure Section