Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

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

Models: 4758 4759 4760 4389 4390 4456

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DC CONTROL

PART 4

SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

Page 4.3-2

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

Contents

DIAGNOSTIC REPAIR MANUAL AIR-COOLEDAUTOMATIC HOME STANDBY GENERATORS ModelsDIAGNOSTIC REPAIR MANUAL TABLE OF CONTENTSAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPELECTRICAL FORMULAS ENGINE FUEL CONSUMPTIONSTATOR WINDING RESISTANCE VALUES / ROTOR RESISTANCE SPECIFICATIONSSPECIFICATIONS MOUNTING DIMENSIONSSPECIFICATIONS MOUNTING DIMENSIONSMAJOR FEATURES SPECIFICATIONS7 kW, Single Cylinder GH-410 Engine 12 kW and 15 kW, V-twin GT-990 EngineTABLE OF CONTENTS PART GENERAL INFORMATIONAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPSECTION GENERATOR IDENTIFICATIONPART INTRODUCTIONPREPACKAGED INSTALLATION BASICS THE TRANSFER SWITCH / LOAD CENTERSELECTING A LOCATION GROUNDING THE GENERATORPREPACKAGED INSTALLATION BASICS Figure 1. Typical Prepackaged InstallationSECTION PARTPOWER SOURCE AND LOAD LINES SYSTEM CONTROL INTERCONNECTIONSPREPACKAGED INSTALLATION BASICS Figure 2. Proper Fuel InstallationPREPARATION BEFORE USE GENERALFUEL REQUIREMENTS SECTIONTESTING, CLEANING AND DRYING VISUAL INSPECTIONMETERS THE VOMMEASURING AC FREQUENCY MEASURING CURRENTMEASURING RESISTANCE TESTING, CLEANING AND DRYINGELECTRICAL UNITS OHMS LAWTESTING, CLEANING AND DRYING SECTIONTESTING, CLEANING AND DRYING SECTIONINSULATION RESISTANCE THE MEGOHMMETERTESTING, CLEANING AND DRYING 2. Repeat Step 1 at Pin Location 3 Wire 66A and Stator Lead3. Repeat Step 1 at Pin Location 7 Wire 6. and Stator Lead Figure 3. C2 Connector Pin Location Numbers Female SideCLEANING THE GENERATOR ROTOR INSULATION RESISTANCE TESTDRYING THE GENERATOR TESTING, CLEANING AND DRYINGENGINE-GENERATOR PROTECTIVE DEVICES Figure 1. Engine Protective Switches on an Air-Cooled EngineSECTION PARTOPERATING INSTRUCTIONS CONTROL PANELSECTION PARTOPERATING INSTRUCTIONS TO SELECT AUTOMATIC OPERATIONMANUAL TRANSFER TO STANDBY AND MANUAL STARTUP SECTIONMANUAL SHUTDOWN AND RETRANSFER BACK TO UTILITY SECTIONOPERATING INSTRUCTIONS PARTAUTOMATIC OPERATING PARAMETERS AUTOMATIC OPERATING SEQUENCESSECTION PARTAUTOMATIC OPERATING SEQUENCES CHART AUTOMATIC OPERATING PARAMETERSSECTION PARTPART AC GENERATORS TABLE OF CONTENTS2.3 Troubleshooting Flow Charts 2.4 Diagnostic Tests Air-cooled, Prepackaged Automatic Standby GeneratorsROTOR ASSEMBLY DESCRIPTION & COMPONENTSTHE AC GENERATOR ENGINE-GENERATOR DRIVE SYSTEMSTATOR ASSEMBLY DESCRIPTION & COMPONENTSBRUSH HOLDER AND BRUSHES OTHER AC GENERATOR COMPONENTSSECTION DESCRIPTION & COMPONENTSPART Figure 5. Excitation Circuit BreakerOPERATIONAL ANALYSIS ROTOR RESIDUAL MAGNETISMFIELD BOOST Figure 2. Field Boost Circuit SchematicOPERATION SECTIONOPERATIONAL ANALYSIS PARTTROUBLESHOOTING 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 SectionSECTION PARTTROUBLESHOOTING FLOWCHARTS SECTIONPART AC GENERATORSTROUBLESHOOTING FLOWCHARTS SECTIONPART AC GENERATORSTROUBLESHOOTING FLOWCHARTS SECTIONPART AC GENERATORSDIAGNOSTIC TESTS SAFETYTEST 1- CHECK MAIN CIRCUIT BREAKER SECTIONTEST 2- CHECK AC OUTPUT VOLTAGE TEST 3- TEST EXCITATION CIRCUIT BREAKERDIAGNOSTIC TESTS SECTIONTEST 4- FIXED EXCITATION TEST ROTOR AMP DRAW TEST DIAGNOSTIC TESTSSECTION PARTTEST 5 WIRE CONTINUITY TEST 6 - CHECK FIELD BOOSTDIAGNOSTIC TESTS SECTIONTEST 7 TESTING THE STATOR WITH A VOM DIAGNOSTIC TESTSSECTION PARTTEST 8 - RESISTANCE CHECK OF ROTOR CIRCUIT DIAGNOSTIC TESTSSECTION PARTTEST 9 - CHECK BRUSHES AND SLIP RINGS DIAGNOSTIC TESTSSECTION PARTTEST 10 - TEST ROTOR ASSEMBLY TEST 12 - CHECK AND ADJUST ENGINE GOVERNORTEST 11 - CHECK AC OUTPUT FREQUENCY DIAGNOSTIC TESTSDIAGNOSTIC TESTS Figure 9. Engine Governor Adjustment Single Cylinder EnginesFigure 10. Engine Governor Adjustment V-twin Engines Figure 11. Full Load Speed Adjust ScrewV-twin EnginesTEST 13 - CHECK AND ADJUST VOLTAGE REGULATOR TEST 15 - CHECK FOR OVERLOAD CONDITIONTEST 14 - CHECK VOLTAGE AND FREQUENCY UNDER LOAD TEST 16 - CHECK ENGINE CONDITIONPART V-TYPE PREPACKAGED TRANSFER SWITCHES TABLE OF CONTENTSAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPFigure 1. Exploded View of V-Type Prepackaged Transfer Switch SECTIONDESCRIPTION & COMPONENTS PARTTRANSFER MECHANISM Figure 2. Load Connected to Utility Power SourceFigure 3. Load Connected to Standby Power Source SECTIONTRANSFER RELAY NEUTRAL LUGMANUAL TRANSFER HANDLE TERMINAL BLOCKFUSE HOLDER Figure 6. Transfer Switch Terminal BlockSECTION PARTOPERATIONAL ANALYSIS Figure 1. Wiring Diagram and SchematicV-TYPE PREPACKAGED TRANSFER SWITCHES SECTIONUTILITY SOURCE VOLTAGE AVAILABLE Figure 2. Utility Source Power AvailableSECTION PARTOPERATIONAL ANALYSIS UTILITY SOURCE VOLTAGE FAILUREFigure 3. Generator Power Available, Waiting to Transfer SECTIONTRANSFER TO STANDBY SECTIONPART OPERATIONAL ANALYSISFigure 5. Generator Powering Load SECTIONOPERATIONAL ANALYSIS PARTUTILITY RESTORED Figure 6. Utility Restored, Generator Still Providing Output to LoadV-TYPE PREPACKAGED TRANSFER SWITCHES SECTIONUTILITY RESTORED, TRANSFER SWITCH DE-ENERGIZED Figure 7. Utility Restored, Transfer Relay De-energizedSECTION PARTUTILITY RESTORED, RETRANSFER BACK TO UTILITY Figure 8. Utility Restored, Retransfer Back to UtilitySECTION PARTTRANSFER SWITCH IN UTILITY Figure 9. Transfer Switch in UTILITYV-TYPE PREPACKAGED TRANSFER SWITCHES SECTIONTROUBLESHOOTING FLOW CHARTS INTRODUCTION TO TROUBLESHOOTINGSECTION PARTTROUBLESHOOTING FLOW CHARTS V-TYPE PREPACKAGED TRANSFER SWITCHESSECTION PARTTEST 21- CHECK VOLTAGE AT TERMINAL LUGS E1, E2 DIAGNOSTIC TESTSSECTION PARTTEST 22 - CHECK VOLTAGE AT STANDBY CLOSING COIL C2 DIAGNOSTIC TESTSSECTION PARTTEST 24- CHECK MANUAL TRANSFER SWITCH OPERATION TEST 23 - TEST TRANSFER RELAY TRDIAGNOSTIC TESTS SECTIONTEST 25- TEST LIMIT SWITCH XB1 DIAGNOSTIC TESTSSECTION PARTTEST 26 - CHECK 23 AND WIRING/CONNECTIONS TEST 27- CHECK VOLTAGE AT TERMINAL LUGS N1, N2DIAGNOSTIC TESTS SECTIONUTILITY 2 TERMINALS TEST 29- CHECK VOLTAGE AT UTILITY CLOSING COIL C1TEST 28 - CHECK VOLTAGE AT UTILITY 1 AND DIAGNOSTIC TESTSTEST 31 - TEST LIMIT SWITCH XA1 TEST 30 - CHECK FUSES F1 AND F2DIAGNOSTIC TESTS SECTIONTEST 33 - CONTINUITY TEST OF WIRING C2 TEST 34 - CHECK N1 AND N2 WIRINGTEST 32 - CONTINUITY TEST OF WIRING C1 DIAGNOSTIC TESTSTEST 35 - CHECK TRANSFORMER TX DIAGNOSTIC TESTS7. Disconnect wire N1 and wire N2 from transformer TX SECTIONDIAGNOSTIC TESTS SECTIONPART Figure 6. Transformer TXPART DC CONTROL TABLE OF CONTENTSAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPDESCRIPTION AND COMPONENTS TERMINAL STRIP / INTERCONNECTION TERMINALTRANSFORMER TX CIRCUIT BOARDWIRE WIRESECTION PARTAUTO-OFF-MANUAL SWITCH 15 AMP FUSE5 AMP FUSE Figure 5. 15 Amp Fuse Figure 4. The AUTO-OFF-MANUAL SwitchSECTION PARTDESCRIPTION AND COMPONENTS Figure 6. Control Panel Component IdentificationSECTION OPERATIONAL ANALYSISPART INTRODUCTIONSECTION PARTOPERATIONAL ANALYSIS DC CONTROLINITIAL DROPOUT OF UTILITY SOURCE VOLTAGE SECTIONOPERATIONAL ANALYSIS PARTSECTION PARTOPERATIONAL ANALYSIS PageUTILITY VOLTAGE DROPOUT AND ENGINE CRANKING SECTIONOPERATIONAL ANALYSIS PARTSECTION PARTOPERATIONAL ANALYSIS DC CONTROLENGINE STARTUP AND RUNNING SECTIONOPERATIONAL ANALYSIS PARTSECTION PARTOPERATIONAL ANALYSIS DC CONTROLINITIAL TRANSFER TO THE STANDBY SOURCE SECTIONOPERATIONAL ANALYSIS PARTSECTION PARTOPERATIONAL ANALYSIS DC CONTROLUTILITY VOLTAGE RESTORED / RE TRANSFER TO UTILITY Figure 6. Circuit Condition - Utility Voltage RestoredSECTION OPERATIONAL ANALYSISSECTION PARTOPERATIONAL ANALYSIS DC CONTROLENGINE SHUTDOWN SECTIONOPERATIONAL ANALYSIS PARTSECTION PARTOPERATIONAL ANALYSIS DC CONTROLTROUBLESHOOTING FLOW CHARTS SECTIONPART DC CONTROLTROUBLESHOOTING FLOW CHARTS SECTIONPART DC CONTROLTROUBLESHOOTING FLOW CHARTS SECTIONPART DC CONTROLTROUBLESHOOTING FLOW CHARTS SECTIONPART DC CONTROLTROUBLESHOOTING FLOW CHARTS SECTIONPART DC CONTROLTROUBLESHOOTING FLOW CHARTS SECTIONPART DC CONTROLTROUBLESHOOTING FLOW CHARTS SECTIONPART DC CONTROLTEST 41 - CHECK POSITION OF AUTO-OFF MANUAL SWITCH TEST 43- TEST AUTO-OFF-MANUAL SWITCHTEST 42 - TRY A MANUAL START DIAGNOSTIC TESTSDIAGNOSTIC TESTS TEST 44- CHECK WIRE 15/15A/17/239 VOLTAGEFigure 2. AUTO-OFF-MANUAL Switch Test Points SECTIONTEST 46- CHECK BATTERY TEST 45- CHECK 15 AMP FUSEDIAGNOSTIC TESTS SECTIONTEST 47 - CHECK WIRE 56 VOLTAGE TEST 48- TEST STARTER CONTACTOR RELAY V-TWIN ONLYDIAGNOSTIC TESTS Figure 4. The Wire 56 CircuitTEST 49- TEST STARTER CONTACTOR DIAGNOSTIC TESTSSECTION PARTTEST 50- TEST STARTER MOTOR DIAGNOSTIC TESTSSECTION PARTDIAGNOSTIC TESTS SECTIONPART Figure 10. Check Pinion Gear Operation V-TwinDIAGNOSTIC TESTS 1. A fully charged 12 volt battery is requiredSECTION PARTTEST 51 - CHECK FUEL SUPPLY AND PRESSURE DIAGNOSTIC TESTSSECTION PARTTEST 53 - CHECK CIRCUIT BOARD WIRE OUTPUT TEST 52 - TEST FUEL SOLENOIDDIAGNOSTIC TESTS SECTIONTEST 54 - CHECK FUEL SOLENOID TEST 55 - CHECK FOR IGNITION SPARKDIAGNOSTIC TESTS SECTIONTEST 56 - CHECK SPARK PLUGS TEST 57- CHECK ENGINE COMPRESSIONDIAGNOSTIC TESTS SECTIONTEST 58 - CHECK SHUTDOWN WIRE TEST 59 - CHECK AND ADJUST IGNITION MAGNETOSDIAGNOSTIC TESTS SECTIONDIAGNOSTIC TESTS Figure 23. Setting Ignition Magneto Armature Air GapSECTION PARTTEST 60- CHECK OIL PRESSURE SWITCH AND WIRE DIAGNOSTIC TESTSFigure 27. Oil Pressure Switch SECTIONTEST 61- CHECK HIGH OIL TEMPERATURE SWITCH DIAGNOSTIC TESTSFigure 28. Testing the Oil Temperature Switch SECTIONTEST 62 - CHECK AND ADJUST VALVES TEST 63 - CHECK FUEL REGULATORDIAGNOSTIC TESTS 5. When full load has been achieved, connect a frequencyTEST 64 - CHECK BATTERY CHARGE OUTPUT DIAGNOSTIC TESTSSECTION PARTTEST 66 - CHECK AC VOLTAGE AT BATTERY CHARGER TEST 65 - CHECK TRANSFORMER TX VOLTAGE OUTPUTDIAGNOSTIC TESTS SECTIONTEST 68 - CHECK BATTERY CHARGE WINDING HARNESS TEST 67 - CHECK BATTERY CHARGE RELAYDIAGNOSTIC TESTS SECTIONTEST 69 - CHECK BATTERY CHARGER WIRING TEST 70 - CHECK ENGINE RUN WINDINGDIAGNOSTIC TESTS SECTIONTEST 73 - TEST SET EXERCISE SWITCH TEST 71 - CHECK N1 AND N2 VOLTAGEAT THE CIRCUIT BOARD TEST 72 - CHECK UTILITY SENSING VOLTAGETEST 74 - CHECK REMOTE START WIRING IF EQUIPPED TEST 75 - CHECK BATTERY VOLTAGE CIRCUITTEST 76 - CHECK CRANKING AND RUNNING CIRCUITS DIAGNOSTIC TESTSTEST 77 - TEST EXERCISE FUNCTION DIAGNOSTIC TESTSSECTION PARTPART OPERATIONAL TESTS TABLE OF CONTENTSAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPMANUAL TRANSFER SWITCH OPERATION SYSTEM FUNCTIONAL TESTSELECTRICAL CHECKS Figure 1. Manual Operation “V-Type” SwitchGENERATOR TESTS UNDER LOAD SECTIONDANGER DANGERSETTING THE EXERCISE TIMER CHECKING AUTOMATIC OPERATIONSECTION SYSTEM FUNCTIONAL TESTSPART DISASSEMBLY TABLE OF CONTENTSAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPMAJOR DISASSEMBLY MAJOR DISASSEMBLY10.Remove Rotor Bolt Using a 9/16 socket, remove one rotor bolt SECTIONMAJOR DISASSEMBLY SECTIONPART Figure 4. Engine Adapter Supported by 2”x4” Piece of WoodFRONT ENGINE ACCESS MAJOR DISASSEMBLY16.Remove Engine Using a 13mm socket, remove the Figure 9. C1 and C2 Connectors Located on the Engine Divider PanelPART ELECTRICAL DATA TABLE OF CONTENTSAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPWIRING DIAGRAM, 7 KW HOME STANDBY MODELPART DRAWING #0D5700-CSCHEMATIC, 7 KW HOME STANDBY MODELPART DRAWING #0D5701-CWIRING DIAGRAM, 12 & 15 KW HOME STANDBY MODEL 4456-0PART DRAWING #0C7830-CSCHEMATIC, 12 & 15 KW HOME STANDBY MODEL 4456-0PART DRAWING #0C7836-CWIRING DIAGRAM, 7 KW HOME STANDBY MODELPART DRAWING #0D9013-C 1 OFWIRING DIAGRAM, 7 KW HOME STANDBY MODELPART DRAWING #0D9013-C 2 OFSCHEMATIC, 7 KW HOME STANDBY MODELPART DRAWING #0D9014-B 1 OFSCHEMATIC, 7 KW HOME STANDBY MODELPART DRAWING #0D9014-B 2 OFMODEL 4456-1 WIRING DIAGRAM, 12 & 15 KW HOME STANDBYPART DRAWING #0D8500-B 1 OFWIRING DIAGRAM, 12 & 15 KW HOME STANDBY MODEL 4456-1PART DRAWING #0D8500-B 2 OFSCHEMATIC, 12 & 15 KW HOME STANDBY MODEL 4456-1PART DRAWING #0D8501-B 1 OFSCHEMATIC, 12 & 15 KW HOME STANDBY MODEL 4456-1PART DRAWING #0D8501-B 2 OFELECTRICAL DATA PARTPage PART ELECTRICAL DATAELECTRICAL DATA PARTPage Page P/N OE3586/Printed in the USA/1.03/Rev XXXXXXXXXXXXXXXXXXXXXXXXXXX 1. Repair engine, or replace defective parts, or adjust as necessary2. If no engine problems are found, go to Test SECTIONSECTION XXXXXXXXXXXXXXXXXXXXXXXXXXXPART 3.4 provides detailed instructions for performance of each testXXXXXXXXXXXXXXXXXXXXXXXXXXX SECTIONPART SECTION XXXXXXXXXXXXXXXXXXXXXXXXXXXPART XXXXXXXXXXXXXXXXXXXXXXXX