Manuals / Guardian Technologies / Lawn and Garden / Portable Generator

Guardian Technologies 4760, 4456, 4390, 4389 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 4.3-3

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

Contents

AIR-COOLED DIAGNOSTIC REPAIR MANUALAUTOMATIC HOME STANDBY GENERATORS ModelsTABLE OF CONTENTS DIAGNOSTIC REPAIR MANUALAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPELECTRICAL FORMULAS FUEL CONSUMPTION ENGINESTATOR WINDING RESISTANCE VALUES / ROTOR RESISTANCE SPECIFICATIONSMOUNTING DIMENSIONS SPECIFICATIONSMOUNTING DIMENSIONS SPECIFICATIONSSPECIFICATIONS MAJOR FEATURES7 kW, Single Cylinder GH-410 Engine 12 kW and 15 kW, V-twin GT-990 EnginePART GENERAL INFORMATION TABLE OF CONTENTSAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPGENERATOR IDENTIFICATION SECTIONPART INTRODUCTIONTHE TRANSFER SWITCH / LOAD CENTER PREPACKAGED INSTALLATION BASICSSELECTING A LOCATION GROUNDING THE GENERATORFigure 1. Typical Prepackaged Installation PREPACKAGED INSTALLATION BASICSSECTION PARTSYSTEM CONTROL INTERCONNECTIONS POWER SOURCE AND LOAD LINESPREPACKAGED INSTALLATION BASICS Figure 2. Proper Fuel InstallationGENERAL PREPARATION BEFORE USEFUEL REQUIREMENTS SECTIONVISUAL INSPECTION TESTING, CLEANING AND DRYINGMETERS THE VOMMEASURING CURRENT MEASURING AC FREQUENCYMEASURING RESISTANCE TESTING, CLEANING AND DRYINGOHMS LAW ELECTRICAL UNITSTESTING, CLEANING AND DRYING SECTIONSECTION TESTING, CLEANING AND DRYINGINSULATION RESISTANCE THE MEGOHMMETER2. Repeat Step 1 at Pin Location 3 Wire 66A and Stator Lead TESTING, CLEANING AND DRYING3. Repeat Step 1 at Pin Location 7 Wire 6. and Stator Lead Figure 3. C2 Connector Pin Location Numbers Female SideROTOR INSULATION RESISTANCE TEST CLEANING THE GENERATORDRYING THE GENERATOR TESTING, CLEANING AND DRYINGFigure 1. Engine Protective Switches on an Air-Cooled Engine ENGINE-GENERATOR PROTECTIVE DEVICESSECTION PARTCONTROL PANEL OPERATING INSTRUCTIONSSECTION PARTTO SELECT AUTOMATIC OPERATION OPERATING INSTRUCTIONSMANUAL TRANSFER TO STANDBY AND MANUAL STARTUP SECTIONSECTION MANUAL SHUTDOWN AND RETRANSFER BACK TO UTILITYOPERATING INSTRUCTIONS PARTAUTOMATIC OPERATING SEQUENCES AUTOMATIC OPERATING PARAMETERSSECTION PARTAUTOMATIC OPERATING PARAMETERS AUTOMATIC OPERATING SEQUENCES CHARTSECTION PARTTABLE OF CONTENTS PART AC GENERATORS2.3 Troubleshooting Flow Charts 2.4 Diagnostic Tests Air-cooled, Prepackaged Automatic Standby GeneratorsDESCRIPTION & COMPONENTS ROTOR ASSEMBLYTHE AC GENERATOR ENGINE-GENERATOR DRIVE SYSTEMDESCRIPTION & COMPONENTS STATOR ASSEMBLYBRUSH HOLDER AND BRUSHES OTHER AC GENERATOR COMPONENTSDESCRIPTION & COMPONENTS SECTIONPART Figure 5. Excitation Circuit BreakerROTOR RESIDUAL MAGNETISM OPERATIONAL ANALYSISFIELD BOOST Figure 2. Field Boost Circuit SchematicSECTION OPERATIONOPERATIONAL ANALYSIS PARTUse 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 TROUBLESHOOTING FLOWCHARTSSECTION PARTSECTION TROUBLESHOOTING FLOWCHARTSPART AC GENERATORSSECTION TROUBLESHOOTING FLOWCHARTSPART AC GENERATORSSECTION TROUBLESHOOTING FLOWCHARTSPART AC GENERATORSSAFETY DIAGNOSTIC TESTSTEST 1- CHECK MAIN CIRCUIT BREAKER SECTIONTEST 3- TEST EXCITATION CIRCUIT BREAKER TEST 2- CHECK AC OUTPUT VOLTAGEDIAGNOSTIC TESTS SECTIONDIAGNOSTIC TESTS TEST 4- FIXED EXCITATION TEST ROTOR AMP DRAW TESTSECTION PARTTEST 6 - CHECK FIELD BOOST TEST 5 WIRE CONTINUITYDIAGNOSTIC TESTS SECTIONDIAGNOSTIC TESTS TEST 7 TESTING THE STATOR WITH A VOMSECTION PARTDIAGNOSTIC TESTS TEST 8 - RESISTANCE CHECK OF ROTOR CIRCUITSECTION PARTDIAGNOSTIC TESTS TEST 9 - CHECK BRUSHES AND SLIP RINGSSECTION PARTTEST 12 - CHECK AND ADJUST ENGINE GOVERNOR TEST 10 - TEST ROTOR ASSEMBLYTEST 11 - CHECK AC OUTPUT FREQUENCY DIAGNOSTIC TESTSFigure 9. Engine Governor Adjustment Single Cylinder Engines DIAGNOSTIC TESTSFigure 10. Engine Governor Adjustment V-twin Engines Figure 11. Full Load Speed Adjust ScrewV-twin EnginesTEST 15 - CHECK FOR OVERLOAD CONDITION TEST 13 - CHECK AND ADJUST VOLTAGE REGULATORTEST 14 - CHECK VOLTAGE AND FREQUENCY UNDER LOAD TEST 16 - CHECK ENGINE CONDITIONTABLE OF CONTENTS PART V-TYPE PREPACKAGED TRANSFER SWITCHESAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPSECTION Figure 1. Exploded View of V-Type Prepackaged Transfer SwitchDESCRIPTION & COMPONENTS PARTFigure 2. Load Connected to Utility Power Source TRANSFER MECHANISMFigure 3. Load Connected to Standby Power Source SECTIONNEUTRAL LUG TRANSFER RELAYMANUAL TRANSFER HANDLE TERMINAL BLOCKFigure 6. Transfer Switch Terminal Block FUSE HOLDERSECTION PARTFigure 1. Wiring Diagram and Schematic OPERATIONAL ANALYSISV-TYPE PREPACKAGED TRANSFER SWITCHES SECTIONFigure 2. Utility Source Power Available UTILITY SOURCE VOLTAGE AVAILABLESECTION PARTUTILITY SOURCE VOLTAGE FAILURE OPERATIONAL ANALYSISFigure 3. Generator Power Available, Waiting to Transfer SECTIONSECTION TRANSFER TO STANDBYPART OPERATIONAL ANALYSISSECTION Figure 5. Generator Powering LoadOPERATIONAL ANALYSIS PARTFigure 6. Utility Restored, Generator Still Providing Output to Load UTILITY RESTOREDV-TYPE PREPACKAGED TRANSFER SWITCHES SECTIONFigure 7. Utility Restored, Transfer Relay De-energized UTILITY RESTORED, TRANSFER SWITCH DE-ENERGIZEDSECTION PARTFigure 8. Utility Restored, Retransfer Back to Utility UTILITY RESTORED, RETRANSFER BACK TO UTILITYSECTION PARTFigure 9. Transfer Switch in UTILITY TRANSFER SWITCH IN UTILITYV-TYPE PREPACKAGED TRANSFER SWITCHES SECTIONINTRODUCTION TO TROUBLESHOOTING TROUBLESHOOTING FLOW CHARTSSECTION PARTV-TYPE PREPACKAGED TRANSFER SWITCHES TROUBLESHOOTING FLOW CHARTSSECTION PARTDIAGNOSTIC TESTS TEST 21- CHECK VOLTAGE AT TERMINAL LUGS E1, E2SECTION PARTDIAGNOSTIC TESTS TEST 22 - CHECK VOLTAGE AT STANDBY CLOSING COIL C2SECTION PARTTEST 23 - TEST TRANSFER RELAY TR TEST 24- CHECK MANUAL TRANSFER SWITCH OPERATIONDIAGNOSTIC TESTS SECTIONDIAGNOSTIC TESTS TEST 25- TEST LIMIT SWITCH XB1SECTION PARTTEST 27- CHECK VOLTAGE AT TERMINAL LUGS N1, N2 TEST 26 - CHECK 23 AND WIRING/CONNECTIONSDIAGNOSTIC TESTS SECTIONTEST 29- CHECK VOLTAGE AT UTILITY CLOSING COIL C1 UTILITY 2 TERMINALSTEST 28 - CHECK VOLTAGE AT UTILITY 1 AND DIAGNOSTIC TESTSTEST 30 - CHECK FUSES F1 AND F2 TEST 31 - TEST LIMIT SWITCH XA1DIAGNOSTIC TESTS SECTIONTEST 34 - CHECK N1 AND N2 WIRING TEST 33 - CONTINUITY TEST OF WIRING C2TEST 32 - CONTINUITY TEST OF WIRING C1 DIAGNOSTIC TESTSDIAGNOSTIC TESTS TEST 35 - CHECK TRANSFORMER TX7. Disconnect wire N1 and wire N2 from transformer TX SECTIONSECTION DIAGNOSTIC TESTSPART Figure 6. Transformer TXTABLE OF CONTENTS PART DC CONTROLAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPTERMINAL STRIP / INTERCONNECTION TERMINAL DESCRIPTION AND COMPONENTSTRANSFORMER TX CIRCUIT BOARDWIRE WIRESECTION PART15 AMP FUSE AUTO-OFF-MANUAL SWITCH5 AMP FUSE Figure 5. 15 Amp Fuse Figure 4. The AUTO-OFF-MANUAL SwitchPART SECTIONDESCRIPTION AND COMPONENTS Figure 6. Control Panel Component IdentificationOPERATIONAL ANALYSIS SECTIONPART INTRODUCTIONPART SECTIONOPERATIONAL ANALYSIS DC CONTROLSECTION INITIAL DROPOUT OF UTILITY SOURCE VOLTAGEOPERATIONAL ANALYSIS PARTPART SECTIONOPERATIONAL ANALYSIS PageSECTION UTILITY VOLTAGE DROPOUT AND ENGINE CRANKINGOPERATIONAL ANALYSIS PARTPART SECTIONOPERATIONAL ANALYSIS DC CONTROLSECTION ENGINE STARTUP AND RUNNINGOPERATIONAL ANALYSIS PARTPART SECTIONOPERATIONAL ANALYSIS DC CONTROLSECTION INITIAL TRANSFER TO THE STANDBY SOURCEOPERATIONAL ANALYSIS PARTPART SECTIONOPERATIONAL ANALYSIS DC CONTROLFigure 6. Circuit Condition - Utility Voltage Restored UTILITY VOLTAGE RESTORED / RE TRANSFER TO UTILITYSECTION OPERATIONAL ANALYSISPART SECTIONOPERATIONAL ANALYSIS DC CONTROLSECTION ENGINE SHUTDOWNOPERATIONAL ANALYSIS PARTPART SECTIONOPERATIONAL ANALYSIS DC CONTROLSECTION TROUBLESHOOTING FLOW CHARTSPART DC CONTROLSECTION TROUBLESHOOTING FLOW CHARTSPART DC CONTROLSECTION TROUBLESHOOTING FLOW CHARTSPART DC CONTROLSECTION TROUBLESHOOTING FLOW CHARTSPART DC CONTROLSECTION TROUBLESHOOTING FLOW CHARTSPART DC CONTROLSECTION TROUBLESHOOTING FLOW CHARTSPART DC CONTROLSECTION TROUBLESHOOTING FLOW CHARTSPART DC CONTROLTEST 43- TEST AUTO-OFF-MANUAL SWITCH TEST 41 - CHECK POSITION OF AUTO-OFF MANUAL SWITCHTEST 42 - TRY A MANUAL START DIAGNOSTIC TESTSTEST 44- CHECK WIRE 15/15A/17/239 VOLTAGE DIAGNOSTIC TESTSFigure 2. AUTO-OFF-MANUAL Switch Test Points SECTIONTEST 45- CHECK 15 AMP FUSE TEST 46- CHECK BATTERYDIAGNOSTIC TESTS SECTIONTEST 48- TEST STARTER CONTACTOR RELAY V-TWIN ONLY TEST 47 - CHECK WIRE 56 VOLTAGEDIAGNOSTIC TESTS Figure 4. The Wire 56 CircuitDIAGNOSTIC TESTS TEST 49- TEST STARTER CONTACTORSECTION PARTDIAGNOSTIC TESTS TEST 50- TEST STARTER MOTORSECTION PARTSECTION DIAGNOSTIC TESTSPART Figure 10. Check Pinion Gear Operation V-Twin1. A fully charged 12 volt battery is required DIAGNOSTIC TESTSSECTION PARTDIAGNOSTIC TESTS TEST 51 - CHECK FUEL SUPPLY AND PRESSURESECTION PARTTEST 52 - TEST FUEL SOLENOID TEST 53 - CHECK CIRCUIT BOARD WIRE OUTPUTDIAGNOSTIC TESTS SECTIONTEST 55 - CHECK FOR IGNITION SPARK TEST 54 - CHECK FUEL SOLENOIDDIAGNOSTIC TESTS SECTIONTEST 57- CHECK ENGINE COMPRESSION TEST 56 - CHECK SPARK PLUGSDIAGNOSTIC TESTS SECTIONTEST 59 - CHECK AND ADJUST IGNITION MAGNETOS TEST 58 - CHECK SHUTDOWN WIREDIAGNOSTIC TESTS SECTIONFigure 23. Setting Ignition Magneto Armature Air Gap DIAGNOSTIC TESTSSECTION PARTDIAGNOSTIC TESTS TEST 60- CHECK OIL PRESSURE SWITCH AND WIREFigure 27. Oil Pressure Switch SECTIONDIAGNOSTIC TESTS TEST 61- CHECK HIGH OIL TEMPERATURE SWITCHFigure 28. Testing the Oil Temperature Switch SECTIONTEST 63 - CHECK FUEL REGULATOR TEST 62 - CHECK AND ADJUST VALVESDIAGNOSTIC TESTS 5. When full load has been achieved, connect a frequencyDIAGNOSTIC TESTS TEST 64 - CHECK BATTERY CHARGE OUTPUTSECTION PARTTEST 65 - CHECK TRANSFORMER TX VOLTAGE OUTPUT TEST 66 - CHECK AC VOLTAGE AT BATTERY CHARGERDIAGNOSTIC TESTS SECTIONTEST 67 - CHECK BATTERY CHARGE RELAY TEST 68 - CHECK BATTERY CHARGE WINDING HARNESSDIAGNOSTIC TESTS SECTIONTEST 70 - CHECK ENGINE RUN WINDING TEST 69 - CHECK BATTERY CHARGER WIRINGDIAGNOSTIC TESTS SECTIONTEST 71 - CHECK N1 AND N2 VOLTAGE TEST 73 - TEST SET EXERCISE SWITCHAT THE CIRCUIT BOARD TEST 72 - CHECK UTILITY SENSING VOLTAGETEST 75 - CHECK BATTERY VOLTAGE CIRCUIT TEST 74 - CHECK REMOTE START WIRING IF EQUIPPEDTEST 76 - CHECK CRANKING AND RUNNING CIRCUITS DIAGNOSTIC TESTSDIAGNOSTIC TESTS TEST 77 - TEST EXERCISE FUNCTIONSECTION PARTTABLE OF CONTENTS PART OPERATIONAL TESTSAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPSYSTEM FUNCTIONAL TESTS MANUAL TRANSFER SWITCH OPERATIONELECTRICAL CHECKS Figure 1. Manual Operation “V-Type” SwitchSECTION GENERATOR TESTS UNDER LOADDANGER DANGERCHECKING AUTOMATIC OPERATION SETTING THE EXERCISE TIMERSECTION SYSTEM FUNCTIONAL TESTSTABLE OF CONTENTS PART DISASSEMBLYAir-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 SECTIONSECTION MAJOR DISASSEMBLYPART Figure 4. Engine Adapter Supported by 2”x4” Piece of WoodMAJOR DISASSEMBLY FRONT ENGINE ACCESS16.Remove Engine Using a 13mm socket, remove the Figure 9. C1 and C2 Connectors Located on the Engine Divider PanelTABLE OF CONTENTS PART ELECTRICAL DATAAir-cooled, Prepackaged Automatic Standby Generators Models 04389, 04758 6 kW NG, 7 kW LPMODEL WIRING DIAGRAM, 7 KW HOME STANDBYPART DRAWING #0D5700-CMODEL SCHEMATIC, 7 KW HOME STANDBYPART DRAWING #0D5701-CMODEL 4456-0 WIRING DIAGRAM, 12 & 15 KW HOME STANDBYPART DRAWING #0C7830-CMODEL 4456-0 SCHEMATIC, 12 & 15 KW HOME STANDBYPART DRAWING #0C7836-CMODEL WIRING DIAGRAM, 7 KW HOME STANDBYPART DRAWING #0D9013-C 1 OFMODEL WIRING DIAGRAM, 7 KW HOME STANDBYPART DRAWING #0D9013-C 2 OFMODEL SCHEMATIC, 7 KW HOME STANDBYPART DRAWING #0D9014-B 1 OFMODEL SCHEMATIC, 7 KW HOME STANDBYPART DRAWING #0D9014-B 2 OFWIRING DIAGRAM, 12 & 15 KW HOME STANDBY MODEL 4456-1PART DRAWING #0D8500-B 1 OFMODEL 4456-1 WIRING DIAGRAM, 12 & 15 KW HOME STANDBYPART DRAWING #0D8500-B 2 OFMODEL 4456-1 SCHEMATIC, 12 & 15 KW HOME STANDBYPART DRAWING #0D8501-B 1 OFMODEL 4456-1 SCHEMATIC, 12 & 15 KW HOME STANDBYPART DRAWING #0D8501-B 2 OFPART PageELECTRICAL DATA ELECTRICAL DATA PARTPART PageELECTRICAL DATA Page Page 1. Repair engine, or replace defective parts, or adjust as necessary XXXXXXXXXXXXXXXXXXXXXXXXXXX2. If no engine problems are found, go to Test SECTIONXXXXXXXXXXXXXXXXXXXXXXXXXXX SECTIONPART 3.4 provides detailed instructions for performance of each testSECTION PARTXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXX SECTIONPART XXXXXXXXXXXXXXXXXXXXXXXX