Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4390, 4456, 4389, 4760 Section, Troubleshooting Flow Charts, Part, Dc Control

Models: 4758 4759 4760 4389 4390 4456

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SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

PART 4

DC CONTROL

Page 4.3-1

Page 91

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Guardian Technologies 4390, 4456, 4389, 4760, 4759, 4758 manual Section, Troubleshooting Flow Charts, Part, Dc Control

Contents

Models DIAGNOSTIC REPAIR MANUALAIR-COOLED AUTOMATIC HOME STANDBY GENERATORSModels 04389, 04758 6 kW NG, 7 kW LP DIAGNOSTIC REPAIR MANUALTABLE OF CONTENTS Air-cooled, Prepackaged Automatic Standby GeneratorsELECTRICAL FORMULAS SPECIFICATIONS ENGINEFUEL CONSUMPTION STATOR WINDING RESISTANCE VALUES / ROTOR RESISTANCEMOUNTING DIMENSIONS SPECIFICATIONSMOUNTING DIMENSIONS SPECIFICATIONS12 kW and 15 kW, V-twin GT-990 Engine MAJOR FEATURESSPECIFICATIONS 7 kW, Single Cylinder GH-410 EngineModels 04389, 04758 6 kW NG, 7 kW LP TABLE OF CONTENTSPART GENERAL INFORMATION Air-cooled, Prepackaged Automatic Standby GeneratorsINTRODUCTION SECTIONGENERATOR IDENTIFICATION PARTGROUNDING THE GENERATOR PREPACKAGED INSTALLATION BASICSTHE TRANSFER SWITCH / LOAD CENTER SELECTING A LOCATIONPART PREPACKAGED INSTALLATION BASICSFigure 1. Typical Prepackaged Installation SECTIONFigure 2. Proper Fuel Installation POWER SOURCE AND LOAD LINESSYSTEM CONTROL INTERCONNECTIONS PREPACKAGED INSTALLATION BASICSSECTION PREPARATION BEFORE USEGENERAL FUEL REQUIREMENTSTHE VOM TESTING, CLEANING AND DRYINGVISUAL INSPECTION METERSTESTING, CLEANING AND DRYING MEASURING AC FREQUENCYMEASURING CURRENT MEASURING RESISTANCESECTION ELECTRICAL UNITSOHMS LAW TESTING, CLEANING AND DRYINGTHE MEGOHMMETER TESTING, CLEANING AND DRYINGSECTION INSULATION RESISTANCEFigure 3. C2 Connector Pin Location Numbers Female Side TESTING, CLEANING AND DRYING2. Repeat Step 1 at Pin Location 3 Wire 66A and Stator Lead 3. Repeat Step 1 at Pin Location 7 Wire 6. and Stator LeadTESTING, CLEANING AND DRYING CLEANING THE GENERATORROTOR INSULATION RESISTANCE TEST DRYING THE GENERATORPART ENGINE-GENERATOR PROTECTIVE DEVICESFigure 1. Engine Protective Switches on an Air-Cooled Engine SECTIONPART OPERATING INSTRUCTIONSCONTROL PANEL SECTIONSECTION OPERATING INSTRUCTIONSTO SELECT AUTOMATIC OPERATION MANUAL TRANSFER TO STANDBY AND MANUAL STARTUPPART MANUAL SHUTDOWN AND RETRANSFER BACK TO UTILITYSECTION OPERATING INSTRUCTIONSPART AUTOMATIC OPERATING PARAMETERSAUTOMATIC OPERATING SEQUENCES SECTIONPART AUTOMATIC OPERATING SEQUENCES CHARTAUTOMATIC OPERATING PARAMETERS SECTIONAir-cooled, Prepackaged Automatic Standby Generators PART AC GENERATORSTABLE OF CONTENTS 2.3 Troubleshooting Flow Charts 2.4 Diagnostic TestsENGINE-GENERATOR DRIVE SYSTEM ROTOR ASSEMBLYDESCRIPTION & COMPONENTS THE AC GENERATOROTHER AC GENERATOR COMPONENTS STATOR ASSEMBLYDESCRIPTION & COMPONENTS BRUSH HOLDER AND BRUSHESFigure 5. Excitation Circuit Breaker SECTIONDESCRIPTION & COMPONENTS PARTFigure 2. Field Boost Circuit Schematic OPERATIONAL ANALYSISROTOR RESIDUAL MAGNETISM FIELD BOOSTPART OPERATIONSECTION OPERATIONAL ANALYSISPART TROUBLESHOOTING FLOWCHARTSUse 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 SECTIONAC GENERATORS TROUBLESHOOTING FLOWCHARTSSECTION PARTAC GENERATORS TROUBLESHOOTING FLOWCHARTSSECTION PARTAC GENERATORS TROUBLESHOOTING FLOWCHARTSSECTION PARTSECTION DIAGNOSTIC TESTSSAFETY TEST 1- CHECK MAIN CIRCUIT BREAKERSECTION TEST 2- CHECK AC OUTPUT VOLTAGETEST 3- TEST EXCITATION CIRCUIT BREAKER DIAGNOSTIC TESTSPART TEST 4- FIXED EXCITATION TEST ROTOR AMP DRAW TESTDIAGNOSTIC TESTS SECTIONSECTION TEST 5 WIRE CONTINUITYTEST 6 - CHECK FIELD BOOST DIAGNOSTIC TESTSPART TEST 7 TESTING THE STATOR WITH A VOMDIAGNOSTIC TESTS SECTIONPART TEST 8 - RESISTANCE CHECK OF ROTOR CIRCUITDIAGNOSTIC TESTS SECTIONPART TEST 9 - CHECK BRUSHES AND SLIP RINGSDIAGNOSTIC TESTS SECTIONDIAGNOSTIC TESTS TEST 10 - TEST ROTOR ASSEMBLYTEST 12 - CHECK AND ADJUST ENGINE GOVERNOR TEST 11 - CHECK AC OUTPUT FREQUENCYFigure 11. Full Load Speed Adjust ScrewV-twin Engines DIAGNOSTIC TESTSFigure 9. Engine Governor Adjustment Single Cylinder Engines Figure 10. Engine Governor Adjustment V-twin EnginesTEST 16 - CHECK ENGINE CONDITION TEST 13 - CHECK AND ADJUST VOLTAGE REGULATORTEST 15 - CHECK FOR OVERLOAD CONDITION TEST 14 - CHECK VOLTAGE AND FREQUENCY UNDER LOADModels 04389, 04758 6 kW NG, 7 kW LP PART V-TYPE PREPACKAGED TRANSFER SWITCHESTABLE OF CONTENTS Air-cooled, Prepackaged Automatic Standby GeneratorsPART Figure 1. Exploded View of V-Type Prepackaged Transfer SwitchSECTION DESCRIPTION & COMPONENTSSECTION TRANSFER MECHANISMFigure 2. Load Connected to Utility Power Source Figure 3. Load Connected to Standby Power SourceTERMINAL BLOCK TRANSFER RELAYNEUTRAL LUG MANUAL TRANSFER HANDLEPART FUSE HOLDERFigure 6. Transfer Switch Terminal Block SECTIONSECTION OPERATIONAL ANALYSISFigure 1. Wiring Diagram and Schematic V-TYPE PREPACKAGED TRANSFER SWITCHESPART UTILITY SOURCE VOLTAGE AVAILABLEFigure 2. Utility Source Power Available SECTIONSECTION OPERATIONAL ANALYSISUTILITY SOURCE VOLTAGE FAILURE Figure 3. Generator Power Available, Waiting to TransferOPERATIONAL ANALYSIS TRANSFER TO STANDBYSECTION PARTPART Figure 5. Generator Powering LoadSECTION OPERATIONAL ANALYSISSECTION UTILITY RESTOREDFigure 6. Utility Restored, Generator Still Providing Output to Load V-TYPE PREPACKAGED TRANSFER SWITCHESPART UTILITY RESTORED, TRANSFER SWITCH DE-ENERGIZEDFigure 7. Utility Restored, Transfer Relay De-energized SECTIONPART UTILITY RESTORED, RETRANSFER BACK TO UTILITYFigure 8. Utility Restored, Retransfer Back to Utility SECTIONSECTION TRANSFER SWITCH IN UTILITYFigure 9. Transfer Switch in UTILITY V-TYPE PREPACKAGED TRANSFER SWITCHESPART TROUBLESHOOTING FLOW CHARTSINTRODUCTION TO TROUBLESHOOTING SECTIONPART TROUBLESHOOTING FLOW CHARTSV-TYPE PREPACKAGED TRANSFER SWITCHES SECTIONPART TEST 21- CHECK VOLTAGE AT TERMINAL LUGS E1, E2DIAGNOSTIC TESTS SECTIONPART TEST 22 - CHECK VOLTAGE AT STANDBY CLOSING COIL C2DIAGNOSTIC TESTS SECTIONSECTION TEST 24- CHECK MANUAL TRANSFER SWITCH OPERATIONTEST 23 - TEST TRANSFER RELAY TR DIAGNOSTIC TESTSPART TEST 25- TEST LIMIT SWITCH XB1DIAGNOSTIC TESTS SECTIONSECTION TEST 26 - CHECK 23 AND WIRING/CONNECTIONSTEST 27- CHECK VOLTAGE AT TERMINAL LUGS N1, N2 DIAGNOSTIC TESTSDIAGNOSTIC TESTS UTILITY 2 TERMINALSTEST 29- CHECK VOLTAGE AT UTILITY CLOSING COIL C1 TEST 28 - CHECK VOLTAGE AT UTILITY 1 ANDSECTION TEST 31 - TEST LIMIT SWITCH XA1TEST 30 - CHECK FUSES F1 AND F2 DIAGNOSTIC TESTSDIAGNOSTIC TESTS TEST 33 - CONTINUITY TEST OF WIRING C2TEST 34 - CHECK N1 AND N2 WIRING TEST 32 - CONTINUITY TEST OF WIRING C1SECTION TEST 35 - CHECK TRANSFORMER TXDIAGNOSTIC TESTS 7. Disconnect wire N1 and wire N2 from transformer TXFigure 6. Transformer TX DIAGNOSTIC TESTSSECTION PARTModels 04389, 04758 6 kW NG, 7 kW LP PART DC CONTROLTABLE OF CONTENTS Air-cooled, Prepackaged Automatic Standby GeneratorsCIRCUIT BOARD DESCRIPTION AND COMPONENTSTERMINAL STRIP / INTERCONNECTION TERMINAL TRANSFORMER TXPART WIREWIRE SECTIONFigure 5. 15 Amp Fuse Figure 4. The AUTO-OFF-MANUAL Switch AUTO-OFF-MANUAL SWITCH15 AMP FUSE 5 AMP FUSEFigure 6. Control Panel Component Identification SECTIONPART DESCRIPTION AND COMPONENTSINTRODUCTION SECTIONOPERATIONAL ANALYSIS PARTDC CONTROL SECTIONPART OPERATIONAL ANALYSISPART INITIAL DROPOUT OF UTILITY SOURCE VOLTAGESECTION OPERATIONAL ANALYSISPage SECTIONPART OPERATIONAL ANALYSISPART UTILITY VOLTAGE DROPOUT AND ENGINE CRANKINGSECTION OPERATIONAL ANALYSISDC CONTROL SECTIONPART OPERATIONAL ANALYSISPART ENGINE STARTUP AND RUNNINGSECTION OPERATIONAL ANALYSISDC CONTROL SECTIONPART OPERATIONAL ANALYSISPART INITIAL TRANSFER TO THE STANDBY SOURCESECTION OPERATIONAL ANALYSISDC CONTROL SECTIONPART OPERATIONAL ANALYSISOPERATIONAL ANALYSIS UTILITY VOLTAGE RESTORED / RE TRANSFER TO UTILITYFigure 6. Circuit Condition - Utility Voltage Restored SECTIONDC CONTROL SECTIONPART OPERATIONAL ANALYSISPART ENGINE SHUTDOWNSECTION OPERATIONAL ANALYSISDC CONTROL SECTIONPART OPERATIONAL ANALYSISDC CONTROL TROUBLESHOOTING FLOW CHARTSSECTION PARTDC CONTROL TROUBLESHOOTING FLOW CHARTSSECTION PARTDC CONTROL TROUBLESHOOTING FLOW CHARTSSECTION PARTDC CONTROL TROUBLESHOOTING FLOW CHARTSSECTION PARTDC CONTROL TROUBLESHOOTING FLOW CHARTSSECTION PARTDC CONTROL TROUBLESHOOTING FLOW CHARTSSECTION PARTDC CONTROL TROUBLESHOOTING FLOW CHARTSSECTION PARTDIAGNOSTIC TESTS TEST 41 - CHECK POSITION OF AUTO-OFF MANUAL SWITCHTEST 43- TEST AUTO-OFF-MANUAL SWITCH TEST 42 - TRY A MANUAL STARTSECTION DIAGNOSTIC TESTSTEST 44- CHECK WIRE 15/15A/17/239 VOLTAGE Figure 2. AUTO-OFF-MANUAL Switch Test PointsSECTION TEST 46- CHECK BATTERYTEST 45- CHECK 15 AMP FUSE DIAGNOSTIC TESTSFigure 4. The Wire 56 Circuit TEST 47 - CHECK WIRE 56 VOLTAGETEST 48- TEST STARTER CONTACTOR RELAY V-TWIN ONLY DIAGNOSTIC TESTSPART TEST 49- TEST STARTER CONTACTORDIAGNOSTIC TESTS SECTIONPART TEST 50- TEST STARTER MOTORDIAGNOSTIC TESTS SECTIONFigure 10. Check Pinion Gear Operation V-Twin DIAGNOSTIC TESTSSECTION PARTPART DIAGNOSTIC TESTS1. A fully charged 12 volt battery is required SECTIONPART TEST 51 - CHECK FUEL SUPPLY AND PRESSUREDIAGNOSTIC TESTS SECTIONSECTION TEST 53 - CHECK CIRCUIT BOARD WIRE OUTPUTTEST 52 - TEST FUEL SOLENOID DIAGNOSTIC TESTSSECTION TEST 54 - CHECK FUEL SOLENOIDTEST 55 - CHECK FOR IGNITION SPARK DIAGNOSTIC TESTSSECTION TEST 56 - CHECK SPARK PLUGSTEST 57- CHECK ENGINE COMPRESSION DIAGNOSTIC TESTSSECTION TEST 58 - CHECK SHUTDOWN WIRETEST 59 - CHECK AND ADJUST IGNITION MAGNETOS DIAGNOSTIC TESTSPART DIAGNOSTIC TESTSFigure 23. Setting Ignition Magneto Armature Air Gap SECTIONSECTION TEST 60- CHECK OIL PRESSURE SWITCH AND WIREDIAGNOSTIC TESTS Figure 27. Oil Pressure SwitchSECTION TEST 61- CHECK HIGH OIL TEMPERATURE SWITCHDIAGNOSTIC TESTS Figure 28. Testing the Oil Temperature Switch5. When full load has been achieved, connect a frequency TEST 62 - CHECK AND ADJUST VALVESTEST 63 - CHECK FUEL REGULATOR DIAGNOSTIC TESTSPART TEST 64 - CHECK BATTERY CHARGE OUTPUTDIAGNOSTIC TESTS SECTIONSECTION TEST 66 - CHECK AC VOLTAGE AT BATTERY CHARGERTEST 65 - CHECK TRANSFORMER TX VOLTAGE OUTPUT DIAGNOSTIC TESTSSECTION TEST 68 - CHECK BATTERY CHARGE WINDING HARNESSTEST 67 - CHECK BATTERY CHARGE RELAY DIAGNOSTIC TESTSSECTION TEST 69 - CHECK BATTERY CHARGER WIRINGTEST 70 - CHECK ENGINE RUN WINDING DIAGNOSTIC TESTSTEST 72 - CHECK UTILITY SENSING VOLTAGE TEST 73 - TEST SET EXERCISE SWITCHTEST 71 - CHECK N1 AND N2 VOLTAGE AT THE CIRCUIT BOARDDIAGNOSTIC TESTS TEST 74 - CHECK REMOTE START WIRING IF EQUIPPEDTEST 75 - CHECK BATTERY VOLTAGE CIRCUIT TEST 76 - CHECK CRANKING AND RUNNING CIRCUITSPART TEST 77 - TEST EXERCISE FUNCTIONDIAGNOSTIC TESTS SECTIONModels 04389, 04758 6 kW NG, 7 kW LP PART OPERATIONAL TESTSTABLE OF CONTENTS Air-cooled, Prepackaged Automatic Standby GeneratorsFigure 1. Manual Operation “V-Type” Switch MANUAL TRANSFER SWITCH OPERATIONSYSTEM FUNCTIONAL TESTS ELECTRICAL CHECKSDANGER GENERATOR TESTS UNDER LOADSECTION DANGERSYSTEM FUNCTIONAL TESTS SETTING THE EXERCISE TIMERCHECKING AUTOMATIC OPERATION SECTIONModels 04389, 04758 6 kW NG, 7 kW LP PART DISASSEMBLYTABLE OF CONTENTS Air-cooled, Prepackaged Automatic Standby GeneratorsSECTION MAJOR DISASSEMBLYMAJOR DISASSEMBLY 10.Remove Rotor Bolt Using a 9/16 socket, remove one rotor boltFigure 4. Engine Adapter Supported by 2”x4” Piece of Wood MAJOR DISASSEMBLYSECTION PARTFigure 9. C1 and C2 Connectors Located on the Engine Divider Panel FRONT ENGINE ACCESSMAJOR DISASSEMBLY 16.Remove Engine Using a 13mm socket, remove theModels 04389, 04758 6 kW NG, 7 kW LP PART ELECTRICAL DATATABLE OF CONTENTS Air-cooled, Prepackaged Automatic Standby GeneratorsDRAWING #0D5700-C WIRING DIAGRAM, 7 KW HOME STANDBYMODEL PARTDRAWING #0D5701-C SCHEMATIC, 7 KW HOME STANDBYMODEL PARTDRAWING #0C7830-C WIRING DIAGRAM, 12 & 15 KW HOME STANDBYMODEL 4456-0 PARTDRAWING #0C7836-C SCHEMATIC, 12 & 15 KW HOME STANDBYMODEL 4456-0 PARTDRAWING #0D9013-C 1 OF WIRING DIAGRAM, 7 KW HOME STANDBYMODEL PARTDRAWING #0D9013-C 2 OF WIRING DIAGRAM, 7 KW HOME STANDBYMODEL PARTDRAWING #0D9014-B 1 OF SCHEMATIC, 7 KW HOME STANDBYMODEL PARTDRAWING #0D9014-B 2 OF SCHEMATIC, 7 KW HOME STANDBYMODEL PARTDRAWING #0D8500-B 1 OF MODEL 4456-1WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PARTDRAWING #0D8500-B 2 OF WIRING DIAGRAM, 12 & 15 KW HOME STANDBYMODEL 4456-1 PARTDRAWING #0D8501-B 1 OF SCHEMATIC, 12 & 15 KW HOME STANDBYMODEL 4456-1 PARTDRAWING #0D8501-B 2 OF SCHEMATIC, 12 & 15 KW HOME STANDBYMODEL 4456-1 PARTPage PARTELECTRICAL DATA ELECTRICAL DATA PARTPage PARTELECTRICAL DATA Page P/N OE3586/Printed in the USA/1.03/Rev SECTION XXXXXXXXXXXXXXXXXXXXXXXXXXX1. Repair engine, or replace defective parts, or adjust as necessary 2. If no engine problems are found, go to Test3.4 provides detailed instructions for performance of each test SECTIONXXXXXXXXXXXXXXXXXXXXXXXXXXX PARTPART SECTIONXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX SECTIONXXXXXXXXXXXXXXXXXXXXXXXXXXX PART