Guardian Technologies 4456 manual

Models: 4389, 4758 (6 kW NG, 7 kW LP) 4456, 4759 (12 kW NG, 12 kW LP) 4390, 4760 (13 kW, 15 kW LP) DIAGNOSTIC REP AIR MANUAL AUTOM A TIC HOME S T ANDBY GENER A TORS Visit us online at www.guardiangenerators.com DIAGNOSTIC REP AIR MANUAL AIR-COOLED[...]

PART TITLE Specifications 1 General Information 2 AC Generators 3 V-Type Prepackaged Transfer Switches 4 DC Control 5 Operational Tests and Adjustments 6 Disassembly 7 Electrical Data DIAGNOSTIC REP AIR MANUAL Air-cooled, Prepackaged Automatic Standby Generators Models: 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 [...]

TO FIND KNOWN VALUES 1-PHASE 3-PHASE KILOWATTS (kW) Volts, Current, Power Factor E x I E x I x 1.73 x PF 1000 1000 KVA Volts, Current E x I E x I x 1.73 1000 1000 AMPERES kW, Volts, Power Factor kW x 1000 kW x 1000 E E x 1.73 x PF WATTS Volts, Amps, Power Factor Volts x Amps E x I x 1.73 x PF NO. OF ROTOR Frequency, RPM 2 x 60 x Frequency 2 x 60 x [...]

SPECIFICA TIONS Page 2 GENERA TOR Models 04389, 04758 Models 04456, 04759 Model 04390, 04760 Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP Rated Voltage 120/240 120/240 120/240 Rated Max. Continuous Load Current (Amps) 120 Volts** 50.0 NG/58.3 LP 100.0 NG/100.0 LP 108.3 NG/125.0 LP 240 Volts[...]

Page 3 SPECIFICA TIONS MOUNTING DIMENSION S[...]

Page 4 SPECIFICA TIONS MOUNTING DIMENSION S[...]

SPECIFICA TIONS Page 5 MAJOR FEATURES 12 kW and 15 kW, V-twin GT-990 Engine 7 kW, Single Cylinder GH-410 Engine[...]

PART TITLE 1.1 Generator Identification 1.2 Prepackaged Installation Basics 1.3 Preparation Before Use 1.4 Testing, Cleaning and Drying 1.5 Engine-Generator Protective Devices 1.6 Operating Instructions 1.7 Automatic Operating Parameters P ART 1 GENERAL INFORMA TION Air-cooled, Prepackaged Automatic Standby Generators Models: 04389, 04758 (6 kW NG,[...]

SECTION 1.1 GENERA TOR IDENTIFICA TION GENERAL INFORMATION P ART 1 Page 1.1-1 INTRODUC TION 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 [...]

SECTION 1.2 PREP ACKAGED INST ALLA TION BASICS GENERAL INFORMATION INTRODUC TION Information in this section is provided so that the service technician will have a basic knowledge of installation requirements for prepackaged home standby systems. Problems that arise are often related to poor or unauthorized installation practices. A typical prepack[...]

P ART 1 GENERAL INFORMATION SECTION 1.2 PREP ACKAGED INST ALLA TION BASICS Page 1.2-2 Figure 1. Typical Prepackaged Installation[...]

SECTION 1.2 PREP ACKAGED INST ALLA TION BASICS GENERAL INFORMATION POWER SOURCE AND LOAD LINES The utility power supply lines, the standby (generator) supply lines, and electrical load lines must all be connected to the proper terminal lugs in the transfer switch. The following rules apply:In 1-phase systems with a 2-pole transfer switch, connect t[...]

P ART 1 GENERAL INFORMATION SECTION 1.3 PREP ARA TION BEFORE USE GENER AL The installer must ensure that the home standby generator has been properly installed. The system must be inspected carefully following installation. All applicable codes, standards and regulations pertaining to such installations must be strictly complied with. In addition, [...]

SECTION 1.4 TESTING, CLEANING AND DR YING GENERAL INFORMATION VISUAL INSPECTI ON When it becomes necessary to test or troubleshoot a generator, it is a good practice to complete a thorough visual inspection. Remove the access covers and look closely for any obvious problems. Look for the following: ❏ Burned or broken wires, broken wire connectors[...]

SECTION 1.4 TESTING, CLEANING AND DR YING P ART 1 GENERAL INFORMATION 2. Before reading a DC voltage, always set the meter to a higher voltage scale than the anticipated reading. if in doubt, start at the highest scale and adjust the scale downward until correct readings are obtained. 3. The design of some meters is based on the "current flow&[...]

SECTION 1.4 TESTING, CLEANING AND DR YING GENERAL INFORMATION If proper procedures are used, the following conditions can be detected using a VOM: ❏ A "short-to-ground" condition in any stator or rotor winding. ❏ Shorting together of any two parallel stator windings. ❏ Shorting together of any two isolated stator windings. ❏ An op[...]

SECTION 1.4 TESTING, CLEANING AND DR YING P ART 1 GENERAL INFORMATION INSULATION RESISTANCE The insulation resistance of stator and rotor windings is a measurement of the integrity of the insulating materials that separate the electrical windings from the generator steel core. This resistance can degrade over time or due to such contaminants as dus[...]

SECTION 1.4 TESTING, CLEANING AND DR YING GENERAL INFORMATION P ART 1 TESTING ALL STATOR WINDINGS TO GROUND: 1 . Disconnect stator output leads 11 and 44 from the generator main line circuit breaker. 2. Remove stator output leads 22 and 33 from the neutral connection and separate the two leads. 3. Disconnect C2 connector from the side of the contro[...]

SECTION 1.4 TESTING, CLEANING AND DR YING P ART 1 GENERAL INFORMATION 5. Insert a large paper clip into Pin Location No. 1 (Wire 77). Connect the red tester probe to the paper clip. Connect the black tester probe to Stator Lead 33. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page. 6. Repeat Step 5 at [...]

SECTION 1.5 ENGINE-GENERA TOR PROTECTIVE DEVICES GENERAL INFORMATION GENER AL Standby electric power generators will often run unattended for long periods of time. Such operating parameters as (a) engine oil pressure, (b) engine temperature, (c) engine operating speed, and (d) engine cranking and startup are not monitored by an operator during auto[...]

CONTROL PANEL GENERAL: See Figure 1. The front face of this panel mounts (a) an hourmeter, (b) an AUTO-OFF-MANUAL switch ,(c) a 15 amp fuse, (d) a 5 amp fuse, (e) a set exercise switch and (f) the protection systems. HOURMETER: Equipped on some models only. The hourmeter indicates engine-generator operating-time, in hours and tenths of hours. Use t[...]

SECTION 1.6 OPERA TING INSTRUCTIONS THE SET EXERCISE SWITCH: The air-cooled, prepackaged automatic standby generator will start and exercise once every seven (7) days, on a day and at a time of day selected by the owner or operator. The set exercise time switch is provided to select the day and time of day for system exercise. See Page 5.1-3 ("[...]

SECTION 1.6 OPERA TING INSTRUCTIONS 7. Set the generator main line circuit breaker to its "On" or "Closed" position. The generator now powers the electrical loads. MANUAL SHUTDOWN AND RETRANSFER BACK TO "UT ILITY" To shut the generator down and retransfer electrical loads back to the UTILITY position, proceed as follow[...]

GENERAL INFORMATION SECTION 1.7 AUTOMA TIC OPERA TING P ARAMETERS INTRODUC TION When the prepackaged generator is installed in conjunction with a prepackaged transfer switch, either manual or automatic operation is possible. Manual transfer and engine startup, as well as manual shutdown and retransfer are covered in Section 1.6. Selection of fully [...]

SECTION 1.7 AUTOMA TIC OPERA TING P ARAMETERS P ART 1 GENERAL INFORMATION Page 1.7-2 AUTOMATIC OPERATING SEQUENCES CHART SEQ. CONDITION ACTION SENSOR, TIMER OR OTHER 1 Utility source voltage is No action Voltage Dropout Sensor on circuit available. circuit board. 2 Utility voltage dropout below A 15-second timer on circuit Voltage Dropout Sensor an[...]

P ART 2 AC GENERA TORS T ABLE OF CONTENTS PART TITLE 2.1 Description and Components 2.2 Operational Analysis 2.3 Troubleshooting Flow Charts 2.4 Diagnostic Tests Air-cooled, Prepackaged Automatic Standby Generators Models: 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP)[...]

SECTION 2.1 DESCRIPTION & COMPONENTS P ART 2 Page 2.1-1 AC GENERATORS INTRODUC TION The air-cooled, pre-packaged automatic standby system is an easy to install, fully enclosed and self- sufficient electric power system. It is designed especially for homeowners, but may be used in other applications as well. On occurrence of a utility power fail[...]

SECTION 2.1 DESCRIPTION & COMPONENTS AC GENERATORS P ART 2 Page 2.1-2 Figure 2. The 2-Pole Rotor Assembly STATOR ASSEMBLY The stator can houses and retains (a) dual AC power windings, (b) excitation winding, (c) battery charge winding and (d) engine run winding. A total of twelve (12) stator leads are brought out of the stator can as shown in F[...]

SECTION 2.1 DESCRIPTION & COMPONENTS P ART 2 AC GENERATORS Figure 5. Excitation Circuit Breaker VOLTAGE REGULATOR: A typical voltage regulator is shown in Figure 6. Unregulated AC output from the stator excitation winding is delivered to the regulator’s DPE terminals, via Wire 2, the excitation circuit breaker, Wire 162, and Wire 6. The volta[...]

SECTION 2.2 OPERA TIONAL ANAL YSIS AC GENERATORS ROTOR RESIDUAL MAGNETISM The generator revolving field (rotor) may be considered to be a permanent magnet. Some ’residual" magnetism is always present in the rotor. This residual magnetism is sufficient to induce a voltage into the stator AC power windings that is approximately 2-12 volts AC. [...]

SECTION 2.2 OPERA TIONAL ANAL YSIS P ART 2 AC GENERATORS OPERAT ION STARTUP: When the engine is started, residual plus field boost magnetism from the rotor induces a voltage into (a) the stator AC power windings, (b) the stator excitation or DPE windings, (c) the stator battery charge, and (d) engine run winding. In an "on-speed" conditio[...]

SECTION 2.3 TROUBLESHOOTING FLOWCHARTS AC GENERATORS 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 2.4. The first step in using the flow charts is to correctly identify the problem. Once that has been done, locate the problem on the [...]

SECTION 2.3 TROUBLESHOOTING FLOWCHARTS P ART 2 AC GENERATORS Page 2.3-2[...]

SECTION 2.3 TROUBLESHOOTING FLOWCHARTS AC GENERATORS P ART 2 Page 2.3-3[...]

SECTION 2.3 TROUBLESHOOTING FLOWCHARTS P ART 2 AC GENERATORS Page 2.3-4[...]

SECTION 2.4 DIAGNOSTIC TESTS AC GENERATORS INTRODUC TION This section is provided to familiarize the service technician with acceptable procedures for the testing and evaluation of various problems that could be encountered on prepackaged standby generators with air-cooled engine. Use this section of the manual in conjunction with Section 2.3, &quo[...]

SECTION 2.4 DIAGNOSTIC TESTS P ART 2 AC GENERATORS TEST 2 - CHECK AC OUTPUT VOLTAGE DISCUSSION: A volt-ohm-milliammeter (VOM) may be used to check the generator output voltage. Output voltage may be checked at the unit’s main circuit breaker terminals. Refer to the unit’s DATA PLATE for rated line-to-line and line-to-neutral voltages. DANGER: U[...]

SECTION 2.4 DIAGNOSTIC TESTS AC GENERATORS TEST 4 - FIXED EXCITATION TEST /ROTOR AMP DRAW TEST DISCUSSION: Supplying a fixed DC current to the rotor will induce a magnetic field in the rotor. With the generator running, this should create a proportional voltage output from the stator windings. PROCEDURE: 1 . Disconnect Wire 4 from the voltage regul[...]

SECTION 2.4 DIAGNOSTIC TESTS P ART 2 AC GENERATORS 8. Set the AUTO-OFF-MANUAL switch to MANUAL. Once the engine starts, record the AC voltage. 9 . Set the AUTO-OFF-MANUAL switch to OFF. Reconnect Wire 11 and Wire 22. 10. Set VOM to DC amperage. 11. Remove jumper lead connected to Wire 4 and Wire 15. 12. Connect one meter test lead to battery positi[...]

SECTION 2.4 DIAGNOSTIC TESTS AC GENERATORS Figure 4. Field Boost Test Points TEST 7: TESTING THE STATOR WITH A VOM DISCUSSION: A Volt-OHM-Milliammmeter (VOM) can be used to test the stator windings for the following faults: ❏ An open circuit condition ❏ A "short-to-ground" condition ❏ A short circuit between windings Note: The resis[...]

SECTION 2.4 DIAGNOSTIC TESTS P ART 2 AC GENERATORS TEST WINDINGS FOR A SHORT TO GROUND: 13. Make sure all leads are isolated from each other and are not touching the frame. 14. Set a VOM to its "R x 10,000" or "R x 1K" scale and zero the meter 1 5 . Connect one test lead to a clean frame ground. Connect the other test lead to st[...]

SECTION 2.4 DIAGNOSTIC TESTS AC GENERATORS RESULTS: 1. If the resistance reading is correct, check your VOM meters fuse and repeat Test 4. 2. If INFINITY is measured on your VOM meter, go to Test 9. TEST 9 - CHECK BRUSHES AND SLIP RINGS DISCUSSION: The function of the brushes and slip rings is to provide for passage of excitation current from stati[...]

SECTION 2.4 DIAGNOSTIC TESTS P ART 2 AC GENERATORS 14. Connect one meter test lead to Pin 10 (wire 4) of the C2 connector (male side). Connect the other meter test lead to Wire 4 removed from the Voltage regulator. CONTINUITY should be measured. If INFINITY is measured repair or replace wire 4 between the C2 connector and the voltage regulator. RES[...]

SECTION 2.4 DIAGNOSTIC TESTS AC GENERATORS generally proportional to AC frequency. A low or high governor speed will result in a correspondingly low or high AC frequency and voltage output. The governed speed must be adjusted before any attempt to adjust the voltage regulator is made. PROCEDURE (7KW UNITS): 1. Loosen the governor clamp bolt (Figure[...]

SECTION 2.4 DIAGNOSTIC TESTS P ART 2 AC GENERATORS TEST 13 - CHECK AND ADJUST VOLTAGE REGULATOR DISCUSSION: For additional information, refer to description and components Page 2.1-3. PROCEDURE: With the frequency between 61-62 Hertz, slowly turn the slotted potentiometer (Figure 12) until line voltage reads 244-252 volts. NOTE: You must remove the[...]

PART TITLE 3.1 Description and Components 3.2 Operational Analysis 3.3 Troubleshooting Flow Charts 3.4 Diagnostic Tests P ART 3  V -TYPE PREP ACKAGED TRANSFER SWITCHES Air-cooled, Prepackaged Automatic Standby Generators Models: 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) T ABLE OF CONTE[...]

SECTION 3.1 DESCRIPTION & COMPONENTS P ART 3 Page 3.1-1 V-TYPE PREPACKAGED TRANSFER SWITCHES GENER AL The prepackaged, V-Type transfer switch is rated 100 amps at 250 volts maximum. It is available in 2- pole configuration only and, for that reason, is useable with 1-phase systems only. Prepackaged transfer switches do not have an intelligence [...]

SECTION 3.1 DESCRIPTION & COMPONENTS V-TYPE PREPACKAGED TRANSFER SWITCHES P ART 3 Page 3.1-2 TRANSFER MECHANISM The 2-pole transfer mechanism consists of a pair of moveable LOAD contacts, a pair of stationary UTILITY contacts, and a pair of stationary STANDBY contacts. The load contacts can be connected to the utility contacts by a utility clos[...]

SECTION 3.1 DESCRIPTION & COMPONENTS TRANSFER RELAY Transfer relay operation is controlled by a circuit board. That circuit board is a part of a control panel assembly, mounted on the standby generator set. Figure 5 shows the transfer relay pictorially and schematically. Relay operation may be briefly described as follows: 1. Generator battery [...]

SECTION 3.1 DESCRIPTION & COMPONENTS Figure 6. Transfer Switch Terminal Block Terminals used on the terminal block are identified as Utility 1 and 2; 23 and 194. UTILITY 1 AND 2: Interconnect with identically labeled terminals in the generator control panel assembly. This is the utility voltage signal to the circuit board. The signal is deliver[...]

SECTION 3.2 OPERA TIONAL ANAL YSIS P ART 3 Page 3.2-1 V-TYPE PREPACKAGED TRANSFER SWITCHES OPERATIONAL ANALYSIS Figure 1 is a schematic and wiring diagram for a typical V-Type transfer switch. Figure 1. Wiring Diagram and Schematic[...]

SECTION 3.2 OPERA TIONAL ANAL YSIS V-TYPE PREPACKAGED TRANSFER SWITCHES P ART 3 Page 3.2-2 UTILITY SOURCE VOLTAGE AVAILABLE Figure 2 is a schematic representation of the transfer switch with utility source power available. The circuit condition may be briefly described as follows: ❏ Utility source voltage is available to terminal lugs N1 and N2 o[...]

SECTION 3.2 OPERA TIONAL ANAL YSIS P ART 3 Page 3.2-3 V-TYPE PREPACKAGED TRANSFER SWITCHES UTILITY SOURCE VOLTAGE FAILURE If utility source voltage should drop below a preset value, the generator circuit board will sense the dropout. That circuit board will then initiate generator cranking and startup after a time delay circuit times out. Figure 3 [...]

SECTION 3.2 OPERA TIONAL ANAL YSIS V-TYPE PREPACKAGED TRANSFER SWITCHES P ART 3 Page 3-2.4 TRANSFER TO STANDBY The generator circuit board delivers 12 volts DC to the transfer relay, via terminal 194 and back to the circuit board via terminal 23. However, circuit board action holds the Wire 23 circuit open and the transfer relay remains de-energize[...]

SECTION 3.2 OPERA TIONAL ANAL YSIS P ART 3 Page 3.2-5 V-TYPE PREPACKAGED TRANSFER SWITCHES TRANSFER TO STANDBY When the standby coil is energized it pulls the transfer switch mechanism to a overcenter position towards the standby power source side, the transfer switch mechanically snaps to the STANDBY position. On closure of the main contacts to th[...]

SECTION 3.2 OPERA TIONAL ANAL YSIS V-TYPE PREPACKAGED TRANSFER SWITCHES P ART 3 Page 3.2-6 UTILITY RESTORED Utility voltage is restored and is available to terminals N1 and N2. The utility voltage is sensed by the generators circuit board. If it is above a preset value for a preset time interval a transfer back to utility power will occur. Figure 6[...]

SECTION 3.2 OPERA TIONAL ANAL YSIS P ART 3 Page 3.2-7 V-TYPE PREPACKAGED TRANSFER SWITCHES UTILITY RESTORED, TRANSFER SWITCH DE -E E NERGIZED After the preset time interval expires the circuit board will open the Wire 23 circuit to ground. The transfer relay de-energizes, it’s normally closed contacts close, and utility source voltage is delivere[...]

SECTION 3.2 OPERA TIONAL ANAL YSIS V-TYPE PREPACKAGED TRANSFER SWITCHES P ART 3 Page 3.2-8 UTILITY RESTORED, RETRANSFER BACK TO UTILITY As the utility coil pulls the transfer switch to an OVER CENTER position, the switch mechanically snaps to UTILITY. On closure of the main contacts to the utility power source side, Limit Switches XA1 and XB1 are m[...]

SECTION 3.2 OPERA TIONAL ANAL YSIS P ART 3 V-TYPE PREPACKAGED TRANSFER SWITCHES TRANSFER SWITCH IN UTILITY When the transfer switch returns to the UTILITY side, generator shutdown occurs after approximately one (1) minute. Figure 9. Transfer Switch in UTILITY. Page 3.2-9[...]

SECTION 3.3 TROUBLESHOOTING FLOW CHARTS INTRODUCTION TO TROUBLESHOOTING The first step in troubleshooting is to correctly identify the problem. Once that is done, the cause of the problem can be found by performing the tests in the appropriate flow chart. Test numbers assigned in the flow charts are identical to test numbers in section 3.4, Diagnos[...]

SECTION 3.3 TROUBLESHOOTING FLOW CHARTS P ART 3 V-TYPE PREPACKAGED TRANSFER SWITCHES Page 3.3-2[...]

SECTION 3.4 DIAGNOSTIC TESTS V-TYPE PREPACKAGED TRANSFER SWITCHES GENER AL Test numbers in this section correspond to the numbered tests in Section 3.3, "Troubleshooting Flow Charts". When troubleshooting, first identify the problem. Then, perform the diagnostic tests in the sequence given in the flow charts. TEST 21 - CHECK VOLTAGE AT TE[...]

SECTION 3.4 DIAGNOSTIC TESTS P ART 3 V-TYPE PREPACKAGED TRANSFER SWITCHES d. Actuate the generator main line circuit breaker to its "On" or "Closed" position. The utility power supply to the transfer switch must be turned OFF. e. Set the generator AUTO-OFF-MANUAL switch to AUTO. (1) The generator should crank and start. ( 2 ) Wh[...]

SECTION 3.4 DIAGNOSTIC TESTS TEST 23 - TEST TRANSFER RELAY TR DISCUSSION: In automatic operating mode, the transfer relay must be energized by circuit board action or standby source power will not be available to the standby closing coil. Without standby source power, the closing coil will remain de-energized and transfer to "Standby" wil[...]

SECTION 3.4 DIAGNOSTIC TESTS P ART 3 V-TYPE PREPACKAGED TRANSFER SWITCHES DISCUSSION: In automatic operating mode, when utility source voltage drops below a preset level, the engine should crank and start. On engine startup, an "engine warm-up timer" on the generator circuit board should start timing. When that timer has timed out (about [...]

SECTION 3.4 DIAGNOSTIC TESTS TEST 26 - CHECK 23 AND 194 WIRING/CONNE CTIONS DISCUSSION: An open circuit in the transfer switch control wiring can prevent a transfer action from occurring. In the auto mode, the circuit board supplies +12 VDC to Wire 194. This DC voltage is supplied to the transfer relay (TR) at Terminal Location A . The opposite sid[...]

SECTION 3.4 DIAGNOSTIC TESTS PROCEDURE: 1. Make sure that all main line circuit breakers in the utility line to the transfer switch are “On” or “Closed.” 2. Test for utility source line-to-line voltage across terminal lugs N1 and N2 (see Figure 1). Normal utility source voltage should be indicated. RESULTS: 1. If low or no voltage is indica[...]

SECTION 3.4 DIAGNOSTIC TESTS 6. Set the generator main line circuit breaker to its "On" or "Closed" position. 7 . Set the generator AUTO-OFF-MANUAL switch to AUTO. a. The generator should crank and start. b . About 15 seconds after engine startup, the transfer relay should energize and transfer to the ’Standby" source sho[...]

SECTION 3.4 DIAGNOSTIC TESTS P ART 3 V-TYPE PREPACKAGED TRANSFER SWITCHES 3. To prevent interaction, disconnect Wire 126 and Wire "A" from the limit switch terminals. 4. Set a VOM to its "R x 1 " scale and zero the meter. 5. Connect the VOM test leads across the two limit switch terminals from which Wires A and 126 were removed.[...]

SECTION 3.4 DIAGNOSTIC TESTS V-TYPE PREPACKAGED TRANSFER SWITCHES a . Connect the negative meter lead to the ground lug. INFINITY should be measured. b. Connect the negative meter lead to Wire 23 at ICT or terminal strip. INFINITY should be measured. c . Connect the negative meter lead to Wire 194 at ICT or terminal strip. INFINITY should be measur[...]

SECTION 3.4 DIAGNOSTIC TESTS P ART 3 12.Connect one test lead to TX terminal 1. Connect the other test lead to TX terminal 7. INFINITY should be measured. 13. Connect one test lead to TX terminal 10. Connect the other test lead t TX terminal 7. INFINITY should be measured. RESULTS: For steps 5, 6, and 7, replace transformer if an open is indicated,[...]

PART TITLE 4.1 Description and Components 4.2 Operational Analysis 4.3 Troubleshooting Flow Charts 4.4 Diagnostic Tests P ART 4 DC CONTROL Air-cooled, Prepackaged Automatic Standby Generators Models: 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) T ABLE OF CONTENTS[...]

SECTION 4.1 DESCRIPTION AND COMPONENTS P ART 4 Page 4.1-1 3DC CONTROL GENER AL This section will familiarize the reader with the various components that make up the DC control system. Major DC control system components that will be covered include the following: ❏ A Terminal Strip / Interconnection Terminal ❏ A Transformer (TX) ❏ A Circuit Bo[...]

SECTION 4.1 DESCRIPTION AND COMPONENTS DC CONTROL P ART 4 Page 4.1-2 J1 PIN WIRE CIRCUIT FUNCTION 1 4 Field boost current to rotor (about 9-10 volts DC). 2 86 Low oil pressure shutdown. Automatic shutdown occurs when Wire 85 is grounded by loss of oil pressure to the LOP. 3 23 Switched to ground for Transfer Relay (TR) operation. 4 194 12 VDC outpu[...]

The circuit board mounts a crank relay (K1) and a run relay (K2, see Figure 4). Crank relay (K1) is energized by circuit board action during both manual and automatic startup to crank the engine. Cranking is accomplished in crank-rest cycles, with the first cycle being 15 seconds on and 15 seconds off. After the first crank-rest cycle, the remainin[...]

Page 4.1-4 SECTION 4.1 DESCRIPTION AND COMPONENTS DC CONTROL P ART 4 Figure 6. Control Panel Component Identification[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS P ART 4 DC CONTROL Page 4.2-1 Figure 1. Circuit Condition - Utility Source Voltage Available INTRODUC TION This "Operational Analysis" is intended to familiarize the service technician with the operation of the DC control system on prepackaged units with air-cooled engine. A thorough understanding of how[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS DC CONTROL P ART 4 Page 4.2-2[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS P ART 4 DC CONTROL INITIAL DROPOUT OF UTILITY SOURCE VOLTAGE Refer to Figure 2, above. Should a "Utility" power source failure occur, circuit condition may be briefly described as follows: The circuit board constantly senses for an acceptable "Utility" source voltage, via transfer switch fuses [...]

Page 4.2-4 SECTION 4.2 OPERA TIONAL ANAL YSIS DC CONTROL P ART 4[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS P ART 4 DC CONTROL UTILITY VOLTAGE DROPOUT AND ENGINE CRANKING After fifteen (15) seconds and when the circuit board’s 15-second timer has timed out, if "Utility" voltage is still below 60 percent of nominal, circuit board action will energize the circuit board’s crank and run relays (K1 and K2) simu[...]

Page 4.2-6 SECTION 4.2 OPERA TIONAL ANAL YSIS DC CONTROL P ART 4[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS P ART 4 DC CONTROL ENGINE STARTUP AND RUNNING With the fuel solenoid open and ignition occurring, the engine starts. Engine startup and running may be briefly described as follows: An AC voltage/frequency signal is delivered to the circuit board from the generator engine run winding, via Wire 66A. When AC frequenc[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS DC CONTROL P ART 4 Page 4.2-8[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS P ART 4 DC CONTROL Page 4.2-9 INITIAL TRANSFER TO THE "STANDBY" SOURCE The generator is running, the circuit board’s "engine warm-up timer" is timing, and generator AC output is available to transfer switch terminal lugs E1 and E2 and to the open contacts on the transfer relay. Initial transf[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS DC CONTROL P ART 4 Page 4.2-10[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS P ART 4 DC CONTROL Page 4.2-11 UTILITY VOLTAGE RESTORED / RE - TRANSFER TO UTILITY The "Load" is powered by the "Standby" power supply. The circuit board continues to seek an acceptable "Utility" source voltage. On restoration of "Utility" source voltage, the following event[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS DC CONTROL P ART 4 Page 4.2-12[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS P ART 4 DC CONTROL Page 4.2-13 ENGINE SHUTDOWN Following retransfer back to the "Utility" source, an "engine cool-down timer" on the circuit board starts timing. When that timer has timed out (approximately one minute), circuit board action will de-energize the circuit board’s run relay (K2).[...]

SECTION 4.2 OPERA TIONAL ANAL YSIS DC CONTROL P ART 4 Page 4.2-14[...]

SECTION 4.3 TROUBLESHOOTING FLOW CHARTS P ART 4 Page 4.3-1 DC CONTROL[...]

SECTION 4.3 TROUBLESHOOTING FLOW CHARTS DC CONTROL P ART 4 Page 4.3-2[...]

SECTION 4.3 TROUBLESHOOTING FLOW CHARTS P ART 4 DC CONTROL Page 4.3-3[...]

SECTION 4.3 TROUBLESHOOTING FLOW CHARTS DC CONTROL P ART 4 Page 4.3-4[...]

SECTION 4.3 TROUBLESHOOTING FLOW CHARTS P ART 4 DC CONTROL Page 4.3-5[...]

SECTION 4.3 TROUBLESHOOTING FLOW CHARTS DC CONTROL P ART 4 Page 4.3-6[...]

SECTION 4.3 TROUBLESHOOTING FLOW CHARTS P ART 4 DC CONTROL Page 4.3-7[...]

SECTION 4.4 DIAGNOSTIC TESTS INTRODUCT ION Perform these "Diagnostic Tests" in conjunction with the "Troubleshooting Flow Charts" of Section 4.3. The test procedures and methods presented in this section are not exhaustive. We could not possibly know of, evaluate and advise the service trade of all conceivable ways in which test[...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 DC CONTROL PROCEDURE: Disconnect all wires from switch terminals, to prevent interaction. Then, use a volt-ohm-milliammeter (VOM) to test for continuity across switch terminals as shown in the following chart. Reconnect all wires and verify correct positions when finished. RESULTS: 1. Replace AUTO-OFF-MANUAL swi[...]

SECTION 4.4 DIAGNOSTIC TESTS 7. Connect the positive (+) test lead to the AUTO-OFF- MANUAL switch Terminal 4, Wire 17/178. Connect the negative (-) test lead to a clean frame ground. Battery voltage should be measured. 8. Connect the positive (+) test lead to Pin location 11, wire 17 at the J1 connector on the circuit board. Connect the negative (-[...]

SECTION 4.4 DIAGNOSTIC TESTS a. An average reading of 1.260 indicates the battery is 100% charged. b . An average reading of 1.230 means the battery is 75% charged. c . An average reading of 1.200 means the battery is 50% charged. d. An average reading of 1.170 indicates the battery is 25% charged. C. Test Battery Condition: 1. If the difference be[...]

SECTION 4.4 DIAGNOSTIC TESTS Figure 5. The Starter Contactor Relay PROCEDURE: 1 Set a VOM to measure DC voltage. 2. Connect the positive (+) meter test lead to the Wire 13 connector. Connect the negative (-) meter test lead to a clean frame ground. Battery voltage should be measured. 3. Connect the positive (+) meter test lead to the Wire 16 connec[...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 Figure 7. The Starter Contactor (V-twin Units) RESULTS: 1. If battery voltage was indicated in Step 1, but NOT in Step 2b, replace the starter contactor. 2 . If battery voltage was indicated in Step 2b, but the engine did NOT crank, go on to Test 50. TEST 50 - TEST STARTER MOTOR CONDITIONS AFFECTING STARTER MOTO[...]

SECTION 4.4 DIAGNOSTIC TESTS DC CONTROL Figure 10. Check Pinion Gear Operation (V-Twin) Figure 11. Check Pinion Gear Operation (Single Cylinder) TOOLS FOR STARTER PERFORMANCE TEST: The following equipment may be used to complete a performance test of the starter motor: ❏ A clamp-on ammeter. ❏ A tachometer capable of reading up to 10,000 rpm. ?[...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 DC CONTROL Figure 14. Test Bracket REMOVE STARTER MOTOR: It is recommended that the starter motor be removed from the engine when testing starter motor performance. Assemble starter to test bracket and clamp test bracket in vise, Figure 15. TESTING STARTER MOTOR: 1. A fully charged 12 volt battery is required. 2[...]

SECTION 4.4 DIAGNOSTIC TESTS DC CONTROL 4 . A starter motor in good condition will be within the following specifications: Single Cylinder V-twin Minimum rpm 800 4500 Maximum Amps 9 50 Figure 15. Testing Starter Motor Performance TEST 51 - CHECK FUEL SUPPLY AND PRESS URE DISCUSSION: The air-cooled prepackaged generator was factory tested and adjust[...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 TEST 52 - TEST FUEL SOLENOID Note: This test is for fuel regulators equipped with idle circuit port only. See Figure 16. These units have an additional 1/4” fuel hose. DISCUSSION: When the Fuel Solenoid (FS) is energized, gas pressure is available internally to the on demand Fuel Regulator. Gas pressure will t[...]

SECTION 4.4 DIAGNOSTIC TESTS DC CONTROL 4 . If the engine cranks but does not start and battery voltage was measured in Steps 2, 3 and 4, and CONTINUITY was NOT measured in Step 6, repair or replace Wire 0 between the Control Panel ground connection and the Fuel Solenoid terminal. If CONTINUITY was measured in Step 6, proceed to Test 52 or test 54 [...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 DC CONTROL 3. Attach the spark plug lead to the spark tester terminal. 4. Crank the engine while observing the spark tester. If spark jumps the tester gap, you may assume the engine ignition system is operating satisfactorily. NOTE: The engine flywheel must rotat e at 350 rpm (or higher) to obtain a good te s t [...]

SECTION 4.4 DIAGNOSTIC TESTS 1. Remove both spark plugs. 2. Insert a compression gauge into either cylinder. 3. Crank the engine until there is no further increase in pressure. 4. Record the highest reading obtained. 5. Repeat the procedure for the remaining cylinder and record the highest reading. RESULTS: The difference in pressure between the tw[...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 4. Tighten both mounting screws. 5. To remove the thickness gauge, rotate the flywheel. 6. Repeat the above procedure for the second magneto. Figure 23. Setting Ignition Magneto (Armature) Air Gap 7. Repeat Test 55 and check for spark across the spark tester gap. 8. If air gap was not out of adjustment, test gro[...]

SECTION 4.4 DIAGNOSTIC TESTS DC CONTROL 12. Now repeat Step 11 with the negative meter test lead connected to Connector “C” (Figure 26). 1 3 . Now check the flywheel magnet by holding a screwdriver at the extreme end of its handle and with its point down. When the tip of the screwdriver is moved to within 3/4 inch (19mm) of the magnet, the blad[...]

SECTION 4.4 DIAGNOSTIC TESTS DC CONTROL P ART 4 the switch terminals. a. Set a VOM to its "R x 1" scale and zero the meter. b. Connect the VOM test leads across the switch terminals. With engine shut down, the meter should read CONTINUITY. c. Connect Wire 86 to Wire 0 for starting purposes only. After engine starts, remove Wire 86 from Wi[...]

SECTION 4.4 DIAGNOSTIC TESTS DC CONTROL P ART 4 9. Heat the oil in the container. When the thermometer reads approximately 274°-294° F. (134°-146° C.), the VOM should indicate CONTINUITY. RESULTS: 1 . If the switch fails Step 4, or Steps 8-9, replace the switch. 2. If INFINITY was NOT measured in Step 5, repair or replace Wire 85 between the Ci[...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 DC CONTROL meter to the output lugs of the generator main line circuit breaker. The fuel regulator is fitted with one (7 kW), or two (12 & 15 kW) adjustment screws. While watching the frequency meter, slowly turn the adjustment screw(s) clockwise or counterclockwise one at a time until highest frequency is r[...]

SECTION 4.4 DIAGNOSTIC TESTS TEST 65 - CHECK TRANSFORMER (TX) VOLTAGE OUTPUT DISCUSSION: The Transformer (TX) is a STEP DOWN type and has two functions. It supplies approximately 16 VAC to the control panel circuit board for utility sensing. It also supplies approximately 16 VAC to the battery charger for trickle charging. A defective transformer w[...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 Figure 33. Battery Charge Relay Test Points TEST 67 - CHECK BATTERY CHARGE RELAY (BC R) DISCUSSION: The battery charge relay is used to switch the AC source delivered to the battery charger. When the BCR is de-energized, the Normally Closed (NC) contacts deliver AC power from the transformer. When the BCR is ene[...]

SECTION 4.4 DIAGNOSTIC TESTS Figure 34. C2 Connector Pin Locations (Male Side) 4. Connect one test lead to Connector C2 Pin Location 1 (Wire 77). Connect the other test lead to the end of Wire 77 which was previously removed from the BCR. CONTINUITY should be measured. 5. Connect one test lead to Connector C2 Pin Location 2 (Wire 66). Connect the o[...]

SECTION 4.4 DIAGNOSTIC TESTS RESULTS: 1. If CONTINUITY is not measured in Step 5, repair or replace Wire 66A between Connector C2 and Connector J1 at the circuit board. 2. If CONTINUITY was not measured in Step 6, repair or replace Wire 55 between Connector C2 and the ground terminal. 3. If CONTINUITY was measured in both Step 5 and Step 6, go to T[...]

SECTION 4.4 DIAGNOSTIC TESTS 6. Connect one meter test lead to Wire 351 (previously removed from SW2). Connect the other meter test lead to Pin Location J3 (Wire 351). CONTINUITY should be measured. 7. Connect one meter test lead to Wire 351 (previously removed from SW2). Connect the other meter test lead to the ground terminal. INFINITY should be [...]

SECTION 4.4 DIAGNOSTIC TESTS P ART 4 J1-4, Wire 194 I f CONTINUITY was measured, go to Step 4. Average nominal resistance reading: 110-120 ohms. J1-5, Wire 56 I f CONTINUITY was measured, go to Step 5. Average nominal resistance reading V-twin (SCR): 150- 160 ohms, Single Cylinder (SC): 4 ohms. J1-10, Wire 15A I f CONTINUITY was measured, repair or[...]

PART TITLE 5.1 System Functional Tests P ART 5 OPERA TIONAL TESTS Air-cooled, Prepackaged Automatic Standby Generators Models: 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) T ABLE OF CONTENTS[...]

SECTION 5.1 SYSTEM FUNCTIONAL TESTS INTRODUC TION Following home standby electric system installation and periodically thereafter, the system should be tested Functional tests of the system include the following: ❏ Manual transfer switch operation. ❏ System voltage tests. ❏ Generator Tests Under Load. ❏ Testing automatic operation. Before p[...]

SECTION 5.1 SYSTEM FUNCTIONAL TESTS 2. Set the generator AUTO-OFF-MANUAL switch to the “OFF “ position. 3 . Turn off all loads connected to the transfer switch terminals T1 and T2. 4. Turn on the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker). The transfer switch is now electri[...]

SECTION 5.1 SYSTEM FUNCTIONAL TESTS OPERATIONAL TESTS AND ADJUSTMENTS P ART 5 Page 5.1-3 and T2. Apply an electrical load equal to the full rated wattage/amperage capacity of the installed generator. 1 0 .Connect an accurate AC voltmeter and a frequency meter across terminal lugs E1 and E2. Voltage should be greater than 230 volts; frequency should[...]

PART TITLE 6.1 Major Disassembly 6.2 Torque Specifications P ART 6 DISASSEMBL Y Air-cooled, Prepackaged Automatic Standby Generators Models: 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) T ABLE OF CONTENTS[...]

MAJOR DISASSEM BLY STATOR/ROTOR/ENGINE REMOVAL: For stator removal, follow Steps 1-14. For rotor removal, follow Steps 1-15. For Engine removal follow Steps 1-16. 1. Remove door. 2. Set the AUTO-OFF-MANUAL switch to OFF. Disconnect battery cables. Remove Fuse F1. Remove the utility power source to the generator. Turn off fuel supply to the generato[...]

SECTION 6.1 MAJOR DISASSEMBL Y DISASSEMBLY P ART 6 Page 6.1-2 Figure 3 13. Remove Muffler: Using a 13mm socket, remove the four muffler hold down bolts. Remove the four exhaust manifold nuts. Remove the muffler and muffler base panel. 14. Stator Removal: Using a 13mm socket, remove the two nuts from the alternator mounting bracket/rubber mounts. Li[...]

SECTION 6.1 MAJOR DISASSEMBL Y P ART 6 DISASSEMBLY Figure 7. Removing the Rotor 16. Remove Engine: Using a 13mm socket, remove the two engine mount nuts, and ground wires. Remove the engine. 17. Reverse the previous steps to re-assemble. Figure 8. Removing the Engine FRONT ENGINE ACCESS 1 . Follow Stator/Rotor/Engine removal procedures, Steps 1-5. [...]

DWG # TITLE 0D5700-C WIRING DIAGRAM, 7 KW HSB MODEL 4389-0 0D5701-C SCHEMATIC, 7 KW HSB MODEL 4389-0 0C7830-C WIRING DIAGRAM, 12 & 15 KW HSB MODEL 4456-0 & 4390-0 0C7836-C SCHEMATIC, 12 & 15 KW HSB MODEL 4456-0 & 4390-0 0D9013-C WIRING DIAGRAM, 7 KW HSB MODEL 4389-1 0D9014-B SCHEMATIC, 7 KW HSB MODEL 4389-1 0D8500-B WIRING DIAGRAM, [...]

WIRING DIAGRAM, 7 KW HOME ST ANDBY MODEL 4389-0 P ART 7 ELECTRICAL DATA Page 7.1-1 DRAWING #0D5700-C[...]

SCHEMA TIC, 7 KW HOME ST ANDBY MODEL 4389-0 ELECTRICAL DATA P ART 7 Page 7.1-2 DRAWING #0D5701-C[...]

WIRING DIAGRAM, 12 & 15 KW HOME ST ANDBY MODEL 4456-0 & 4390-0 P ART 7 ELECTRICAL DATA Page7.1-3 DRAWING #0C7830-C[...]

SCHEMA TIC, 12 & 15 KW HOME ST ANDBY MODEL 4456-0 & 4390-0 ELECTRICAL DATA P ART 7 Page 7.1-4 DRAWING #0C7836-C[...]

WIRING DIAGRAM, 7 KW HOME ST ANDBY MODEL 4389-1 P ART 7 ELECTRICAL DATA Page 7.1-5 DRAWING #0D9013-C (1 OF 2)[...]

WIRING DIAGRAM, 7 KW HOME ST ANDBY MODEL 4389-1 ELECTRICAL DATA P ART 7 Page 7.1-6 DRAWING #0D9013-C (2 OF 2)[...]

SCHEMA TIC, 7 KW HOME ST ANDBY MODEL 4389-1 P ART 7 ELECTRICAL DATA Page 7.1-7 DRAWING #0D9014-B (1 OF 2)[...]

SCHEMA TIC, 7 KW HOME ST ANDBY MODEL 4389-1 ELECTRICAL DATA P ART 7 Page 7.1-8 DRAWING #0D9014-B (2 OF 2)[...]

WIRING DIAGRAM, 12 & 15 KW HOME ST ANDBY MODEL 4456-1 & 4390-1 P ART 7 ELECTRICAL DATA DRAWING #0D8500-B (1 OF 2) Page 7.1-9[...]

WIRING DIAGRAM, 12 & 15 KW HOME ST ANDBY MODEL 4456-1 & 4390-1 ELECTRICAL DATA P ART 7 Page 7.1-10 DRAWING #0D8500-B (2 OF 2)[...]

SCHEMA TIC, 12 & 15 KW HOME ST ANDBY MODEL 4456-1 & 4390-1 P ART 7 ELECTRICAL DATA Page 7.1-11 DRAWING #0D8501-B (1 OF 2)[...]

SCHEMA TIC, 12 & 15 KW HOME ST ANDBY MODEL 4456-1 & 4390-1 ELECTRICAL DATA P ART 7 Page 7.1-12 DRAWING #0D8501-B (2 OF 2)[...]

P ART 7 ELECTRICAL DATA NOTES Page 7.1-13[...]

ELECTRICAL DATA NOTES P ART 7 Page 7.1-14[...]

P ART 7 ELECTRICAL DATA NOTES Page 7.1-15[...]

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PO Box 297 Whitewater, WI 53190 www.guardiangenerators.com P/N OE3586/Printed in the USA/1.03/Rev. 3.04[...]

XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX SECTION X.X XXXXXXXXXXXXXXXXXXXXXXXXXXX RESULTS: 1. Repair engine, or replace defective part(s), or adjust as necessary. 2. If no engine problems are found, go to Test 7. PART X Page 149[...]

PART X 3.4 provides detailed instructions for performance of each test. XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX SECTION X.X XXXXXXXXXXXXXXXXXXXXXXXXXXX[...]

XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX SECTION X.X XXXXXXXXXXXXXXXXXXXXXXXXXXX PROCEDURE: 1 . Set the AUTO-OFF-MANUAL switch (SW1) to MANUAL. The generator should start. Set SW1 back to AUTO. Verify that SW1 has been in AUTO for weekly exercise to function. 2. Verify that DIP Switch 2 (REMOTE NOT AUTO) on the circuit board is set to the [...]

PART X XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX SECTION X.X XXXXXXXXXXXXXXXXXXXXXXXXXXX[...]