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Guardian 4389 Repair Manual

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AIR-COOLED
DIAGNOSTIC
DIAGNOSTIC
REPAIR MANUAL
REPAIR MANUAL
AUTOMATIC HOME STANDBY GENERATORS
Models:
4389, 4758 (6 kW NG, 7 kW LP)
4456, 4759 (12 kW NG, 12 kW LP)
4390, 4760 (13 kW, 15 kW LP)
Visit us online at
www.guardiangenerators.com

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Summary of Contents for Guardian 4389

  • Page 1 AIR-COOLED DIAGNOSTIC DIAGNOSTIC REPAIR MANUAL REPAIR MANUAL Visit us online at AUTOMATIC HOME STANDBY GENERATORS www.guardiangenerators.com Models: 4389, 4758 (6 kW NG, 7 kW LP) 4456, 4759 (12 kW NG, 12 kW LP) 4390, 4760 (13 kW, 15 kW LP)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS PART TITLE Specifications General Information DIAGNOSTIC AC Generators V-Type Prepackaged Transfer Switches REPAIR MANUAL DC Control Operational Tests and Adjustments Electrical Data 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) Page 1...

  • Page 4: Electrical Formulas

    ELECTRICAL FORMULAS 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 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 x 1.73 x PF...

  • Page 5: Specifications

    SPECIFICATIONS GENERATOR 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 6: Mounting Dimensions

    SPECIFICATIONS MOUNTING DIMENSIONS 0D3739 [12"] [27.7"] [29.25"] Ø30.2mm [Ø1.19"] 207 [8.14"] TRANSFER SWITCH (IF SUPPLIED) LIFTING HOLES 4-CORNERS "DO NOT LIFT BY THE ROOF" 604 [23.5"] 1193 [47"] 716 [2 622 [24.5"] 1232 [48.5"] LEFT SIDE VIEW FRONT VIEW 76.2mm [3.00"] PEA GRAVEL MINUMUM **ALL DIMENSIONS IN:...
  • Page 7 SPECIFICATIONS MOUNTING DIMENSIONS OUTL 914mm [ 36.0" ] MINIMUM OPEN AREA ALL AROUND UNIT 490.7 [19.3"] AIR INTAKE 1172.3 [46.2"] 3/4" NPT FUEL INLET GAS PRESSURE OF 11-14" WATER COLUMN REQUIRED CABLE ACCESS HOLES. (REMOVE PLUG FOR ACCESS) GROUNDING LUG [10.2"] [5.9"] RIGHT SIDE VIEW...
  • Page 8 SPECIFICATIONS MAJOR FEATURES 7 kW, Single Cylinder GH-410 Engine CONTROL PANEL DATA DECAL EXHAUST AIR FILTER ENCLOSURE FUEL REGULATOR (BEHIND BATTERY COMPARTMENT) OIL FILTER BATTERY COMPARTMENT 12 kW and 15 kW, V-twin GT-990 Engine AIR FILTER DATA CONTROL DECAL PANEL OIL DIPSTICK EXHAUST ENCLOSURE...

  • Page 9: General Information

    TABLE OF CONTENTS PART TITLE Generator Identification PART 1 Prepackaged Installation Basics Preparation Before Use GENERAL Testing, Cleaning and Drying INFORMATION Engine-Generator Protective Devices Operating Instructions Automatic Operating Parameters 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) Page 7...
  • Page 10 SECTION 1.1 PART 1 GENERAL INFORMATION GENERATOR IDENTIFICATION INTRODUCTION This Diagnostic Repair Manual has been prepared especially for the purpose of familiarizing service per- sonnel with the testing, troubleshooting and repair of 0055555 Item # air-cooled, prepackaged automatic standby genera- tors.
  • Page 11 SECTION 1.2 PART 1 GENERAL INFORMATION PREPACKAGED INSTALLATION BASICS INTRODUCTION The pressure at which LP gas is delivered to the gen- erator fuel solenoid valve may vary considerably, depending on ambient temperatures. In cold weather, Information in this section is provided so that the ser- supply pressures may drop to “zero”.
  • Page 12 SECTION 1.2 PART 1 GENERAL INFORMATION PREPACKAGED INSTALLATION BASICS Figure 1. Typical Prepackaged Installation Page 10...
  • Page 13 SECTION 1.2 PART 1 GENERAL INFORMATION PREPACKAGED INSTALLATION BASICS POWER SOURCE AND LOAD LINES SYSTEM CONTROL INTERCONNECTIONS The utility power supply lines, the standby (generator) Prepackaged home standby generators are equipped supply lines, and electrical load lines must all be con- with a terminal board identified with the following ter- nected to the proper terminal lugs in the transfer minals: (a) UTILITY 1, (b) UTILITY 2, (c) 23, and (d)
  • Page 14 SECTION 1.3 PART 1 GENERAL INFORMATION PREPARATION BEFORE USE GENERAL ENGINE OIL RECOMMENDATIONS The installer must ensure that the home standby gen- The primary recommended oil for units with air- erator has been properly installed. The system must cooled, single cylinder or V-Twin engines is synthetic be inspected carefully following installation.
  • Page 15 SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING VISUAL INSPECTION THE VOM When it becomes necessary to test or troubleshoot a A meter that will permit both voltage and resistance to generator, it is a good practice to complete a thor- be read is the “volt-ohm-milliammeter”...
  • Page 16 SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING 3. The design of some meters is based on the “current flow” theory while others are based on the “electron flow” theory. The “current flow” theory assumes that direct current flows from the positive (+) to the negative (-).
  • Page 17 SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING With alternating current (AC), the electrons flow first resistance remains the same, and current will in one direction, then reverse and move in the oppo- decrease when resistance Increases and voltage site direction.
  • Page 18 SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING leads together. FOLLOW THE MEGGER MANUFAC- HI-POT TESTER: TURER’S INSTRUCTIONS CAREFULLY. A “Hi-Pot” tester is shown in Figure 1. The model Use a megger power setting of 500 volts. Connect shown is only one of many that are commercially one megger test lead to the junction of all stator available.
  • Page 19 SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING a. Turn the Hi-Pot tester switch OFF. 3. Repeat Step 1 at Pin Location 7 (Wire 6). and Stator Lead 11. b. Plug the tester cord into a 120 volt AC wall socket and set its voltage selector switch to 4.
  • Page 20 SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING 5. Turn the tester switch “On” and make sure the pilot light CLEANING THE GENERATOR has turned on. Caked or greasy dirt may be loosened with a soft 6. Observe the breakdown lamp, then turn the tester switch brush or a damp cloth.
  • Page 21 SECTION 1.5 PART 1 GENERAL INFORMATION ENGINE-GENERATOR PROTECTIVE DEVICES GENERAL LOW OIL SWITCH HIGH TEMP SWITCH Standby electric power generators will often run unat- tended for long periods of time. Such operating para- meters as (a) engine oil pressure, (b) engine temper- ature, (c) engine operating speed, and (d) engine cranking and startup are not monitored by an operator during automatic operation.

  • Page 22: Operating Instructions

    SECTION 1.6 PART 1 GENERAL INFORMATION OPERATING INSTRUCTIONS CONTROL PANEL a. Select AUTO for fully automatic operation. b. When AUTO is selected, circuit board will moni- tor utility power source voltage. GENERAL: c. Should utility voltage drop below a preset level See Figure 1 for appropriate control panel configura- and remain at such a low level for a preset time, tions.
  • Page 23 SECTION 1.6 PART 1 GENERAL INFORMATION OPERATING INSTRUCTIONS THE SET EXERCISE SWITCH: TO SELECT AUTOMATIC OPERATION The air-cooled, prepackaged automatic standby gen- The following procedure applies only to those installa- erator will start and exercise once every seven (7) tions in which the air-cooled, prepackaged automatic days, on a day and at a time of day selected by the standby generator is installed in conjunction with a owner or operator.
  • Page 24 SECTION 1.6 PART 1 GENERAL INFORMATION OPERATING INSTRUCTIONS 6. Let the engine warm up and stabilize for a minute or two 3. Set the generator AUTO-OFF-MANUAL switch to OFF. at no-load. Wait for the engine to come to a complete stop. 7.
  • Page 25 SECTION 1.7 PART 1 GENERAL INFORMATION AUTOMATIC OPERATING PARAMETERS INTRODUCTION PHASE 4 - ENGINE STARTUP AND RUNNING: The circuit board senses that the engine is running by When the prepackaged generator is installed in receiving a voltage/frequency signal from the engine conjunction with a prepackaged transfer switch, run windings.
  • Page 26 SECTION 1.7 PART 1 GENERAL INFORMATION AUTOMATIC OPERATING PARAMETERS AUTOMATIC OPERATING SEQUENCES CHART SEQ. CONDITION ACTION SENSOR, TIMER OR OTHER Utility source voltage is No action Voltage Dropout Sensor on circuit available. circuit board. Utility voltage dropout below A 15-second timer on circuit Voltage Dropout Sensor and 15 60% of rated voltage occurs.

  • Page 27: Ac Generators

    TABLE OF CONTENTS PART TITLE Description and Components PART 2 Operational Analysis Troubleshooting Flow Charts Diagnostic Tests AC GENERATORS 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) Page 25...
  • Page 28 SECTION 2.1 PART 2 AC GENERATORS DESCRIPTION & COMPONENTS INTRODUCTION directly coupled to the engine crankshaft (see Figure 1), and mounted in an enclosure. Both the engine and The air-cooled, pre-packaged automatic standby sys- generator rotor are driven at approximately 3600 rpm, to provide a 60 Hz AC output.
  • Page 29 SECTION 2.1 PART 2 AC GENERATORS DESCRIPTION & COMPONENTS Wire 4 connects to the positive (+) brush and Wire 0 to the negative (-) brush. Wire 0 connects to frame ground. Rectified and regulated excitation current, as well as current from a field boost circuit, are delivered to the rotor windings via Wire 4, and the positive (+) brush and slip ring.
  • Page 30 SECTION 2.1 PART 2 AC GENERATORS DESCRIPTION & COMPONENTS Figure 5. Excitation Circuit Breaker VOLTAGE REGULATOR: A typical voltage regulator is shown in Figure 6. Unregulated AC output from the stator excitation Figure 6. Typical Voltage Regulator winding is delivered to the regulator’s DPE terminals, via Wire 2, the excitation circuit breaker, Wire 162, A single red lamp (LED) glows during normal opera- and Wire 6.

  • Page 31: Operational Analysis

    SECTION 2.2 PART 2 AC GENERATORS OPERATIONAL ANALYSIS ROTOR RESIDUAL MAGNETISM Field boost voltage is reduced from that of battery voltage by the resistor action and, when read with a DC voltmeter, will be approximately 9 or 10 volts DC. The generator revolving field (rotor) may be consid- ered to be a permanent magnet.

  • Page 32: Dc Control

    SECTION 2.2 PART 2 AC GENERATORS OPERATIONAL ANALYSIS OPERATION Initially, the AC power winding voltage sensed by the regulator is low. The regulator reacts by increasing the flow of excitation current to the rotor until voltage STARTUP: increases to a desired level. The regulator then main- tains the desired voltage.

  • Page 33: Troubleshooting Flowcharts

    SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS GENERAL Use the “Flow Charts” in conjunction with the detailed The first step in using the flow charts is to correctly instructions in Section 2.4. Test numbers used in the identify the problem. Once that has been done, locate flow charts correspond to the numbered tests in the problem on the following pages.
  • Page 34 SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS Problem 1 - Generator Produces Zero Voltage or Residual Voltage (Continued) TEST 4 - PERFORM FIXED EXCITATION / ROTOR AMP DRAW TEST 7 - TEST STATOR GOOD TEST 10 - TEST ROTOR ASSEMBLY PERFORM STATOR INSULATION...
  • Page 35 SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS Problem 2 - Generator Produces Low Voltage at No-Load TEST 2 - CHECK TEST 11 - CHECK TEST 12 - ADJUST FREQUENCY AND AC OUTPUT AC OUTPUT ENGINE GOVERNOR VOL TAGE O.K. VOL TAGE FREQUENCY FREQUENCY O.K.,...
  • Page 36 SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS Problem 4 - Voltage and Frequency Drop Excessively When Loads Are Applied TEST 14 - CHECK IF RECONFIGURED TO LP GAS, TEST 15 - CHECK BOTH VOLTAGE AND NOT OVERLOADED FOR OVERLAOD VERIFY THAT PROPER FREQUENCY CONDITION...
  • Page 37 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS INTRODUCTION 1. Set a volt-ohm-milliammeter (VOM) to its “R x 1” scale and zero the meter. This section is provided to familiarize the service 2. With the generator shut down, disconnect all wires from technician with acceptable procedures for the testing and evaluation of various problems that could be the main circuit breaker terminals, to prevent interaction.

  • Page 38: Diagnostic Tests

    SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS DANGER: USE EXTREME CAUTION DURING Wire 162, and Wire 6. If the excitation circuit breaker has failed open, excitation current will not be avail- THIS TEST. THE GENERATOR WILL BE RUN- able to the voltage regulator or to the rotor. Stator AC NING.
  • Page 39 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS Figure 3. Voltage Regulator 4. Disconnect Wire 2 from the excitation circuit breaker (CB2) and connect one test lead to that wire. Disconnect Wire 6 from the voltage regulator and con- nect the other test lead to that wire. (5th terminal from top, double check wire number).
  • Page 40 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS RESULTS: supplied to the rotor. Generator AC output voltage will then drop to zero or nearly zero. Refer to Chart in Section 2.4: “Results - Fixed Excitation Test/Rotor Amp Draw Test.” (previous PROCEDURE: page).
  • Page 41 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS TEST 7: TESTING THE STATOR WITH A VOM ing). Note the resistance reading and compare to the specifications in the front of this manual. DISCUSSION: 9. Connect one test lead to Pin 1. Connect the other test A Volt-OHM-Milliammmeter (VOM) can be used to lead to Pin 2 (battery charge winding).
  • Page 42 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS 27.Repeat Step 22 using stator lead Wire 33; Pin 3 TEST 8 - RESISTANCE CHECK OF ROTOR CIRCUIT 28.Repeat Step 22 using stator lead Wire 33; Pin 7 29.Repeat Step 22 using Pin 1; Pin 3 DISCUSSION: 30.Repeat Step 22 using Pin 1;...
  • Page 43 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS 2. Set a VOM to measure resistance. 13.Remove Wire 4 from the voltage regulator. 3. Connect one meter test lead to Pin 9 (Wire 0) of the C2 14.Connect one meter test lead to Pin 10 (Wire 4) of the C2 connector (female side).
  • Page 44 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS 3. When engine has stabilized, read the frequency meter. The no-load frequency should be about 61-63 Hertz. RESULTS: 1. If the AC frequency is high or low, go on to Test 12. 2.
  • Page 45 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS 3. Start the generator; let it stabilize and warm up at no-load. 4. Start unit and apply full load. Use full load speed adjust screw (Figure 10) to adjust frequency to 58 Hz. 4.
  • Page 46 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS PROCEDURE: 3. Apply electrical loads to the generator equal to the rated capacity of the unit. With the frequency between 61-62 Hertz, slowly turn the slotted potentiometer (Figure 11) until line voltage 4.
  • Page 47 TABLE OF CONTENTS PART 3 PART TITLE Description and Components “V-TYPE” Operational Analysis Troubleshooting Flow Charts PREPACKAGED Diagnostic Tests 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) Page 45...
  • Page 48 SECTION 3.1 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DESCRIPTION & COMPONENTS GENERAL ENCLOSURE The prepackaged, “V-Type” transfer switch is rated The standard prepackaged, “V-Type” transfer switch 100 amps at 250 volts maximum. It is available in 2- enclosure is a NEMA 1 type (“NEMA” stands for pole configuration only and, for that reason, is use- “National Electrical Manufacturer’s Association”).
  • Page 49 SECTION 3.1 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DESCRIPTION & COMPONENTS TRANSFER MECHANISM tacts to an overcenter position; limit switch action then opens the circuit and spring force will complete the transfer action to “Standby”. This coil’s bridge rec- The 2-pole transfer mechanism consists of a pair of tifier is also sealed in the coil wrappings.

  • Page 50: Operational Tests And Adjustments

    SECTION 3.1 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DESCRIPTION & COMPONENTS c. When de-energized, the relay’s normally open NEUTRAL LUG contacts are open and its normally-closed con- The standby generator is equipped with an tacts are closed. UNGROUNDED neutral. The neutral lug in the trans- d.
  • Page 51 SECTION 3.1 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DESCRIPTION & COMPONENTS TERMINALS 23 AND 194: These terminals connect the transfer relay to the generator circuit board. See “Transfer Relay” in Section 3.1. FUSE HOLDER The fuse holder holds two (2) fuses, designated as fuses F1 and F2.
  • Page 52 SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS OPERATIONAL ANALYSIS Figure 1 is a schematic for a typical “V-Type” transfer switch. Figure 1. Schematic Page 50...
  • Page 53 SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS Figure 2 is a wiring diagram for a typical “V-Type” transfer switch. Figure 2. Wiring Diagram Page 51...

  • Page 54: Utility Source Voltage Available

    SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS UTILITY SOURCE VOLTAGE AVAILABLE Figure 3 is a schematic representation of the transfer switch with utility source power available. The circuit condi- tion may be briefly described as follows: • Utility source voltage is available to terminal lugs N1 and N2 of the transfer mechanism, transfer switch is in the UTILITY position and source voltage is available to T1, T2 and customer load.

  • Page 55: Utility Source Voltage Failure

    SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS 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 4 is a schematic representation of the transfer switch with generator power available, waiting to transfer.

  • Page 56: Transfer To Standby

    SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS 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-energized.
  • Page 57 SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS 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 the standby power source side, limit switches XA1 and XB1 are mechanically actuated to “arm”...

  • Page 58: Utility Restored

    SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS 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. 12Vdc TRANSER COIL TS TO...
  • Page 59 SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS UTILITY RESTORED, TRANSFER SWITCH DE-ENERGIZED 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 delivered to the utility closing coil (C1), via Wires N1A and N2A, closed Transfer Relay Contacts 1 and 7, and Limit Switch XA1.
  • Page 60 SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS 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 mechanically actuated to “arm”...

  • Page 61: Transfer Switch In Utility

    SECTION 3.2 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS TRANSFER SWITCH IN UTILITY When the transfer switch returns to the utility side, generator shutdown occurs after approximately one (1) minute. 12Vdc TRANSER COIL TS TO OPEN GENERATOR CONTROL PANEL 240VAC OUTPUT BLACK...

  • Page 62: Introduction To Troubleshooting

    SECTION 3.3 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES 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, “Diagnostic Tests.”...
  • Page 63 SECTION 3.3 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES TROUBLESHOOTING FLOW CHARTS Problem 6 - In Automatic Mode, Generator Starts When Loss of Utility Occurs, Generator Shuts Down When Utility Returns But There Is No Retransfer To Utility Power C1 COIL VOLTAGE TEST 29 - CHECK TEST 24 - CHECK REPLACE...
  • Page 64 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS GENERAL PROCEDURE: 1. If the generator engine has started automatically (due to Test numbers in this section correspond to the num- a utility power source outage) and is running, check the bered tests in Section 3.3, “Troubleshooting Flow position of the generator main circuit breaker.
  • Page 65 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS e. Set the generator AUTO-OFF-MANUAL switch GROUND, WHILE BAREFOOT, OR WHILE to AUTO. HANDS OR FEET ARE WET. (1) The generator should crank and start. 4. Disconnect Wire E2 from the standby closing coil (C2). (2) When the generator starts, an “engine Connect one meter test Lead to Wire E2.
  • Page 66 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS RESULTS: DESIRED METER READING CONNECT VOM 1. Replace transfer relay if it is defective. TEST LEADS ACROSS ENERGIZED DE-ENERGIZED 2. If transfer relay checks good go to Test 26. Terminals 6 and 9 Continuity Infinity Terminals 1 and 7...
  • Page 67 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS OFF. FAILURE TO TURN OFF ALL POWER VOLT- 3. See Figure 1. Connect the VOM test probes across AGE SUPPLIES MAY RESULT IN EXTREMELY HAZ- the two outer terminals from which the wires were dis- ARDOUS AND POSSIBLY LETHAL ELECTRICAL connected.
  • Page 68 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS b. If voltage is not present, repair wiring between ATTEMPT THIS TEST WHILE STANDING ON transfer switch and generator control panel. WET OR DAMP GROUND, WHILE BAREFOOT, OR WHILE HANDS OR FEET ARE WET. 7.
  • Page 69 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS RESULTS: b. About 15 seconds after engine startup, the transfer relay should energize and transfer to 1. If voltage reading across the UTILITY 1 and UTILITY 2 the “Standby” source should occur. terminals is zero, go to Test 30.
  • Page 70 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS between the generator and transfer switch, or (b) a defective component in the generator circuit board. See Part 4, “DC Control”. TEST 32 - CONTINUITY TEST OF WIRING (C1) DISCUSSION: This test will ensure that all control wiring has continuity.
  • Page 71 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS and connect one test lead to it. Connect the other test 9. Connect one test lead to Wire N2 removed in Step 7, lead to Terminal Lug E1 of the transfer switch. CONTI- and the other test lead to the ground terminal.
  • Page 72 SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS 8. Connect one test lead to TX Terminal 1. Connect the RESULTS: other test lead to the transformer case. INFINITY For Steps 5, 6, and 7, replace transformer if an open is indicated, or if the resistance value indicated is should be measured.
  • Page 73 TABLE OF CONTENTS PART TITLE Description and Components PART 4 Operational Analysis Troubleshooting Flow Charts DC CONTROL 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) Page 71...
  • Page 74 SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS GENERAL both secondary transformer windings. Reduced volt- age from one secondary winding is delivered to the This section will familiarize the reader with the various circuit board as “Utility” source sensing voltage. Reduced voltage from the other secondary winding is components that make up the DC control system.

  • Page 75: Description And Components

    SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS J1 PIN WIRE CIRCUIT FUNCTION Field boost current to rotor (about 9-10 volts DC). Low oil pressure shutdown. Automatic shutdown occurs when Wire 85 is grounded by loss of oil pressure to the LOP. Switched to ground for Transfer Relay (TR) operation.
  • Page 76 SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS The run relay is energized by circuit board action at 15 AMP FUSE the same time as the crank relay, to energize and open a fuel solenoid valve. This fuse protects the circuit board against excessive current.
  • Page 77 SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS GROUND TERMINAL NEUTRAL BLOCK TRANSFORMER (TX) TERMINAL STRIP STARTER CONTACTOR VOLTAGE REGULATOR RELAY (SCR) (V-TWINS ONLY) BATTERY CHARGER BATTERY CHARGE RELAY (BCR) CIRCUIT BREAKER "DPE" (CB2) 4-TAB TERMINAL BLOCK (TB) GROUND TERMINAL PRINTED CIRCUIT BOARD SET EXERCISE SWITCH (SW2) ACCESSORY OUTLET...
  • Page 78 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS INTRODUCTION 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 the system works is essential to sound and logical troubleshooting.
  • Page 79 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • Utility source voltage is available to transfer switch Terminal Lugs N1/N2. With the transfer switch main con- tacts at their “Utility” side, this source voltage is available to Terminal Lugs T1/T2 and to the “Load” circuits. •...

  • Page 80: Initial Dropout Of Utility Source Voltage

    SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS 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 F1/F2, transfer switch UTILITY 1 and UTILITY 2 terminals, connected wiring, control panel UTILITY 1 and UTILITY 2 terminals, the sensing transformer (TX), and Wires 224/225.
  • Page 81 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • Should utility voltage drop below approximately 60 percent of the nominal source voltage, a 15-second timer on the circuit board will turn on. • In Figure 2, the 15-second timer is still timing and engine cranking has not yet begun. •...

  • Page 82: Utility Voltage Dropout And Engine Cranking

    SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS 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) simultaneously.
  • Page 83 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS contactor (SC). When the SC energizes, its contacts close and battery power is delivered to the starter motor (SM).The engine cranks. • When the circuit board’s run relay (K2) energizes, 12 volts DC is delivered to a fuel solenoid (FS), via Wire 14. The fuel solenoid (FS) energizes open and fuel is available to the engine.

  • Page 84: Engine Startup And Running

    SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS 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.
  • Page 85 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • The “engine warm-up timer” will run for about 15 seconds. When this timer finishes timing, board action will ini- tiate transfer to the STANDBY power source. As shown in Figure 4 (above), the timer is still running and trans- fer has not yet occurred.
  • Page 86 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS 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 avail- able to transfer switch terminal lugs E1 and E2 and to the open contacts on the transfer relay. Initial transfer to the STANDBY power supply may be briefly described as follows: •...
  • Page 87 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS ground. The transfer relay then energizes and its normally open contacts close. • Standby power is now delivered to the standby closing coil (C2), via Wires E1 /E2, the normally open transfer relay contacts, Wire 205, limit switch XB1, Wire B, and a bridge rectifier.
  • Page 88 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS 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 events will occur: •...
  • Page 89 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • The utility closing coil (C1) energizes and moves the main current carrying contacts to their NEUTRAL position. The main contacts move to an over center position past NEUTRAL and spring force closes them to their UTILI- TY side.

  • Page 90: Engine Shutdown

    SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS 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).
  • Page 91 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • The hourmeter (if equipped) connected to Wire 14 will be opened and clock function of the hourmeter will stop. • The battery charge relay (BCR) connected to Wire 14 will be de-energized. This will cause transformer (TX) voltage to power the battery charger again.
  • Page 92 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 8 - Engine Will Not Crank When Utility Power Source Fails TEST 41 - CHECK SWITCH IS TEST 42 - TRY A VERIFY UTILITY POSITION OF IN “AUTO” MANUAL START SOURCE IS “OFF”...
  • Page 93 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 10 - Engine Cranks but Won’t Start TEST 51 - CHECK TEST 53 - CHECK TEST 52 - CHECK FUEL SOLENOID GOOD GOOD FUEL SUPPLY CIRCUIT BOARD (UNITS EQUIPPED WITH IDLE PORT AND PRESSURE WIRE 14 OUTPUT OF FUEL REGULATOR)
  • Page 94 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 11 - Engine Starts Hard and Runs Rough / Lacks Power IF RECONFIGURED TO LP GAS, TEST 55 - CHECK TEST 51 - CHECK VERIFY THAT PROPER GOOD GOOD FOR IGNITION FUEL SUPPLY PROCEDURE WAS FOLLOWED SPARK...
  • Page 95 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 12 - Engine Starts and Runs, Then Shuts Down CHECK FAULT LIGHTS TEST 60 - CHECK OIL LOW OIL PRESSURE SWITCH ILLUMINATED REFILL, REPAIR OR REPLACE AND WIRE 86 TEST 61 - CHECK HIGH INSTALL CORRECTLY OVER TEMP OIL TEMPERATURE...
  • Page 96 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 13 - No Battery Charge TEST 64 - CHECK BATTERY CHARGE OUTPUT UTILITY ON GOOD GOOD GENERATOR OFF GENERATOR GOOD GOOD RUNNING BATTERY CHARGE WORKING TEST 65 - TEST TEST 66 - CHECK AC TEST 67 - TEST TRANSFORMER (TX) VOLTAGE AT...
  • Page 97 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 14 - Unit Starts and Transfer Occurs When Utility Power Is Available TEST 65 - TEST TEST 72 - CHECK TEST 71 - REPLACE TRANSFORMER (TX) UTILITY SENSING GOOD GOOD GOOD CHECK N1 &...
  • Page 98 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 16 - 15 Amp Fuse (F1) Blown FUSE BLOWS TEST 75 - CHECK IMMEDIATELY WHEN BATTERY VOLTAGE REPLACED CIRCUIT FUSE BLOWS WHEN TEST 76 - CHECK PLACED IN “AUTO” OR CRANKING AND “MANUAL”...
  • Page 99 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS INTRODUCTION crank” condition is to determine if the problem is peculiar to automatic operations only or if the engine won’t crank manually either. Perform these “Diagnostic Tests” in conjunction with the “Troubleshooting Flow Charts” of Section 4.3. PROCEDURE: The test procedures and methods presented in this 1.
  • Page 100 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS RESULTS: PROCEDURE 1. Replace AUTO-OFF-MANUAL switch, if defective. (For Problem 1 flow chart, do Steps 1-5 and Step 9 only) (For Problem 2 flow chart, do all steps) 2. For Problem 8 Only: If the switch passes the tests, verify 1.
  • Page 101 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS replace Wire 15A from Terminal 1 to Terminal 3 of SW1. 3. If fuse continues to blow, go to Problem 16. 3. No battery voltage in Step 4. Verify Step 2 and repair or TEST 46- CHECK BATTERY replace Wire 15 from SW1 to J1 connector.
  • Page 102 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 47 - CHECK WIRE 56 VOLTAGE TEST 48- TEST STARTER CONTACTOR RELAY (V-TWIN ONLY) DISCUSSION: DISCUSSION: During an automatic start or when starting manually, a crank relay (K1) on the circuit board should ener- The starter contactor relay (SCR) located in the con- gize.
  • Page 103 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TINUITY is measured in Step 8, replace the starter con- STARTER tactor relay. SWITCH BATTERY 3. If battery voltage is measured in Step 6. proceed to Test 49. TEST 49- TEST STARTER CONTACTOR CONNECTING DIAGRAM DISCUSSION:...
  • Page 104 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS PROCEDURE: CHECKING THE PINION: The battery should have been checked prior to this When the starter motor is activated, the pinion gear test and should be fully charged. should move and engage the flywheel ring gear. If the pinion does not move normally, inspect the pinion for Set a VOM to measure DC voltage (12 VDC).
  • Page 105 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS REMOVE STARTER MOTOR: It is recommended that the starter motor be removed from the engine when testing starter motor perfor- mance. Assemble starter to test bracket and clamp test bracket in vise, Figure 15. TESTING STARTER MOTOR: 1.
  • Page 106 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 51 - CHECK FUEL SUPPLY AND NOTE: Where a primary regulator is used to establish fuel inlet pressure, adjustment of that PRESSURE regulator is usually the responsibility of the fuel supplier or the fuel supply system installer. DISCUSSION: RESULTS: The air-cooled prepackaged generator was factory...
  • Page 107 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS close and 12 volts DC is delivered to Wire 14 and to a repair or replace Wire 14 between 4-tab terminal block fuel solenoid. The solenoid energizes open to allow and the Fuel Solenoid (FS). fuel flow to the engine.
  • Page 108 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 3. Set the AUTO-OFF-MANUAL switch to OFF. Reconnect 3. Attach the spark plug lead to the spark tester terminal. Wire 56 to starter contactor relay or starter contactor. 4. Crank the engine while observing the spark tester. If spark jumps the tester gap, you may assume the engine RESULTS: ignition system is operating satisfactorily.
  • Page 109 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 2. Replace any spark plug having burned electrodes or RESULTS: cracked porcelain. The difference in pressure between the two cylinders should not exceed 25 percent. If the difference is 3. Set gap on new or used spark plugs to 0.030 inch for greater than 25 percent, loss of compression in the single cylinder engines and 0.020 inch for v-twin lowest reading cylinder is indicated.
  • Page 110 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS RESULTS: 5. To remove the thickness gauge, rotate the flywheel. 1. If INFINITY was NOT measured in Step 4, repair or 6. Repeat the above procedure for the second magneto. replace shorted ground Wire 18 between the J1 con- 7.
  • Page 111 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS RESULTS: If sparking still does not occur after adjusting the ENGINE armature air gap, testing the ground wires and per- GROUND forming the basic flywheel test, replace the ignition HARNESS magneto(s). TEST 60- CHECK OIL PRESSURE SWITCH AND WIRE 86 DISCUSSION: If the oil pressure switch contacts have failed in their...
  • Page 112 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 3. Do the following: test lead to a clean frame ground. INFINITY should be measured. If CONTINUITY is measured, repair or a. Disconnect Wire 86 and Wire 0 from the oil replace Wire 86 between the LOP switch and the J1 pressure switch terminals.
  • Page 113 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS Figure 29 5. Re-install the rocker cover gasket, rocker cover and the four (4) screws. Figure 28. Testing the Oil Temperature Switch RESULTS: RESULTS: Adjust valve clearance as necessary, the retest. 1. If the switch fails Step 4, or Steps 8-9, replace the switch.
  • Page 114 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS Unit 120 Volts 240 Volts 7. Turn utility power to the main distribution panel back on. 7 kW 50.0 amps 25.0 amps This can be done by switching the service main breaker 12 kW 100.0 amps 50.0 amps...
  • Page 115 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 65 - CHECK TRANSFORMER (TX) RESULTS: VOLTAGE OUTPUT 1. If line-to-line voltage was NOT measured in Step 2, go to Problem 7, Section 3.3. DISCUSSION: 2. If correct voltage was measured in Step 2, and no volt- The Transformer (TX) is a “step down”...
  • Page 116 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS RESULTS: 1. Replace the battery charge relay if it fails any of the 224A steps in this chart. 225A 2. If the BCR tests good, but still does not function during generator operation, check Wire 14 and Wire 0 connect- ed to the BCR.
  • Page 117 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 4. Connect one test lead to Connector C2 Pin Location 1 2. Set a VOM to measure resistance. (Wire 77). Connect the other test lead to the end of Wire 3. Disconnect Connector C2 from the side of the control 77 which was previously removed from the BCR.
  • Page 118 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 3. Connect one test lead to Wire N1 at the terminal strip in 4. With the meter test leads connected to SW2, depress the generator control panel. Connect the other test lead to and hold the switch activated.
  • Page 119 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 4. If the remote start connections have been used, discon- PROCEDURE: nect the customer wires from the terminal connector at 1. Set a VOM to measure resistance. Wire 178 and Wire 183. 2.
  • Page 120 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS If coil resistance of 113 ohms was mea- c. If each component tests good, there is no short sured, the short is in Wire 194 between the to ground. The fault exists in one of the Wire 14 transfer relay and the terminal strip.
  • Page 121 TABLE OF CONTENTS PART TITLE System Functional Tests PART 5 OPERATIONAL 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) Page 119...

  • Page 122: System Functional Tests

    SECTION 5.1 OPERATIONAL TESTS PART 5 AND ADJUSTMENTS SYSTEM FUNCTIONAL TESTS INTRODUCTION TRANSFER SWITCH MAY RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK. Following home standby electric system installation and periodically thereafter, the system should be 4. Remove the manual transfer handle from the enclosure. tested Functional tests of the system include the 5.
  • Page 123 SECTION 5.1 OPERATIONAL TESTS PART 5 AND ADJUSTMENTS SYSTEM FUNCTIONAL TESTS GENERATOR TESTS UNDER LOAD DANGER To test the generator set with electrical loads applied, THE TRANSFER SWITCH IS NOW ELECTRI- proceed as follows: CALLY “HOT”, CONTACT WITH “HOT” PARTS 1.
  • Page 124 SECTION 5.1 OPERATIONAL TESTS PART 5 AND ADJUSTMENTS SYSTEM FUNCTIONAL TESTS With the generator running and loads powered by 15.Set the AUTO-OFF-MANUAL switch to OFF. The engine generator AC output, turn ON the utility power supply should shut down. to the transfer switch. The following should occur: •...
  • Page 125 TABLE OF CONTENTS PART TITLE Major Disassembly Torque Specifications PART 6 DISASSEMBLY 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) Page 123...

  • Page 126: Major Disassembly

    SECTION 6.1 PART 6 DISASSEMBLY MAJOR DISASSEMBLY MAJOR DISASSEMBLY 7. Remove Exhaust Side Enclosure: Using a 10mm socket with a 2 1/2” extension remove the four (4) bot- tom enclosure bolts, and six (6) side enclosure bolts. STATOR/ROTOR/ENGINE REMOVAL: Remove the enclosure. For stator removal, follow Steps 1-14.
  • Page 127 SECTION 6.1 PART 6 DISASSEMBLY MAJOR DISASSEMBLY Figure 3 14.Stator Removal: Using a 13mm socket, remove the two nuts from the alternator mounting bracket/rubber Figure 5. Rear Bearing Carrier Removed mounts. Lift the back end of the alternator up and place a 2”x 4”...
  • Page 128 SECTION 6.1 PART 6 DISASSEMBLY MAJOR DISASSEMBLY 16.Remove Engine: Using a 13mm socket, remove the the middle of the control panel, connecting to the two engine mount nuts, and ground wires. Remove the back/side enclosure and the engine divider panel. engine.

  • Page 129: Electrical Data

    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 & 4389-2 0D9014-B Air-cooled, Prepackaged SCHEMATIC, 7 KW HSB MODEL 4389-1 & 4389-2 Automatic Standby Generators 0D8500-B WIRING DIAGRAM, 12 &...

  • Page 130: Model 4389-0

    WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-0 DRAWING #0D5700-C NO - REMOTE ALARM - REMOTE ALARM NO - REMOTE START - REMOTE START TRANSFER RELAY COIL TRANSFER RELAY COIL UTILITY FROM T/SW UTILITY FROM T/SW...

  • Page 131: Model 4389-0

    SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-0 DRAWING #0D5701-C Page 129...

  • Page 132: Model 4456-0 & 4390-0

    WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4456-0 & 4390-0 DRAWING #0C7830-C - REMOTE ALARM NO - REMOTE START - REMOTE START TRANSFER RELAY COIL TRANSFER RELAY COIL UTILITY FROM T/SW UTILITY FROM T/SW NEUTRAL CONNECTION Page 130...
  • Page 133 SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4456-0 & 4390-0 DRAWING #0C7836-C Page 131...
  • Page 134 WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4389-1 & 4389-2 GROUP G DRAWING #0D9013-C (1 OF 2) DIAGRAM KEY - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER DIODE DSW - PCB MOUNTED DIP SWITCH...
  • Page 135 WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4389-1 & 4389-2 GROUP G DRAWING #0D9013-C (2 OF 2) CONTROL PANEL BOX 224A 225A CLOSEST TO BEARIN 224A 225A STATOR 225B 225B 224B 224B VOLTAGE REGULATOR AUTO 240V GENERATOR...
  • Page 136 SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4389-1 & 4389-2 GROUP G DRAWING #0D9014-B (1 OF 2) 225A 224A BATTERY 225B CHARGER 224B C2-1 BATTERY CHARGE WINDING C2-4 ENGINE RUN C1-4 WINDING (STATOR) FIELD C1-3 C2-3 ELECTRONIC...
  • Page 137 SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4389-1 & 4389-2 GROUP G DRAWING #0D9014-B (2 OF 2) C2-6 C2-5 225A 240VAC 56VA INPUT 224A 12Vdc RELAY COIL CUSTOMER CONNECTIONS 120V POWER 120V WINDING 240V C1-2 C1-1 BATTERY...
  • Page 138 WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4456-1, 4456-2, 4390-1, 4390-2 GROUP G DRAWING #0D8500-B (1 OF 2) DIAGRAM KEY ENGINE WIRING - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER DIODE DSW - PCB MOUNTED DIP SWITCH BATTERY...
  • Page 139 WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4456-1, 4456-2, 4390-1, 4390-2 GROUP G DRAWING #0D8500-B (2 OF 2) CONTROL PANEL BOX 224A 225A 224A 225A CLOSEST TO BEARING STATOR 225B 225B 224B 224B VOLTAGE REGULATOR 240V GENERATOR AUTO...
  • Page 140 SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4456-1, 4456-2, 4390-1, 4390-2 DRAWING #0D8501-B (1 OF 2) GROUP G 225A 225A 224A 224A BATTERY 225B CHARGER 224B C2-1 BATTERY CHARGE WINDING C2-2 C2-11 ENGINE RUN WINDING C1-4 (STATOR) FIELD...
  • Page 141 SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 4456-1, 4456-2, 4390-1, 4390-2 DRAWING #0D8501-B (2 OF 2) GROUP G C2-6 C2-5 225A 240VAC UTILITY 56VA INPUT 224A 12Vdc RELAY COIL CUSTOMER CONNECTIONS 120V POWER 120V (STATOR) C2-1 C1-1 BATTERY...

  • Page 142: Model 4389-3

    WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-3 DRAWING #0E9014 (1 OF 2) Page 140...

  • Page 143: Model 4389-3

    WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-3 DRAWING #0E9014 (2 OF 2) Page 141...
  • Page 144 SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-0 DRAWING #0E9015 (1 OF 2) Page 142...
  • Page 145 SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-0 DRAWING #0E9015 (2 OF 2) Page 143...

  • Page 146: Model 4456-3 & 4390-3

    WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-3 & 4390-3 DRAWING #0E9016 (1 OF 2) Page 144...

  • Page 147: Model 4456-3 & 4390-3

    WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-3 & 4390-3 DRAWING #0E9016 (2 OF 2) Page 145...
  • Page 148 SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-1 & 4390-1 DRAWING #0E9017 (1 OF 2) Page 146...
  • Page 149 SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-1 & 4390-1 DRAWING #0E9017 (2 OF 2) Page 147...
  • Page 150 WIRING DIAGRAM, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 12 CIRCUIT DRAWING #0E7687 (1 OF 2) Page 148...

  • Page 151: Wiring Diagram

    WIRING DIAGRAM, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 12 CIRCUIT DRAWING #0E7687 (2 OF 2) Page 149...
  • Page 152 WIRING DIAGRAM, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 8 CIRCUIT DRAWING #0E7687A (1 OF 2) Page 150...
  • Page 153 WIRING DIAGRAM, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 8 CIRCUIT DRAWING #0E7687A (2 OF 2) Page 151...
  • Page 154 SCHEMATIC, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 12 CIRCUIT DRAWING #0E7815 (1 OF 2) Page 152...
  • Page 155 SCHEMATIC, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 8 CIRCUIT DRAWING #0E7815 (2 OF 2) Page 153...
  • Page 156 PO Box 297 Whitewater, WI 53190 www.guardiangenerators.com P/N OE3586. Rev. B/Printed in the USA/3.05...

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