Guardian 5240 Diagnostic Repair Manual
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Guardian 5240 Diagnostic Repair Manual

Guardian 5240 Diagnostic Repair Manual

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AIR-COOLED
DIAGNOSTIC
DIAGNOSTIC
REPAIR MANUAL
REPAIR MANUAL
AUTOMATIC STANDBY GENERATORS
MODELS:
5240, 5280 (7 kW NG, 6 kW LP)
5241, 5281 (9 kW NG, 10 kW LP)
5242, 5282 (13 kW NG, 13 kW LP)
5243, 5283 (15 kW NG, 16 kW LP)
5244, 5284 (15 kW NG, 16 kW LP)
www.guardiangenerators.com

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Summary of Contents for Guardian 5240

  • Page 1 AIR-COOLED MODELS: 5240, 5280 (7 kW NG, 6 kW LP) 5241, 5281 (9 kW NG, 10 kW LP) 5242, 5282 (13 kW NG, 13 kW LP) 5243, 5283 (15 kW NG, 16 kW LP) 5244, 5284 (15 kW NG, 16 kW LP)

  • Page 2: Electrical Formulas

    ELECTRICAL FORMULAS TO FIND KNOWN VALUES 1-PHASE 3-PHASE E x I E x I x 1.73 x PF KILOWATTS (kW) Volts, Current, Power Factor 1000 1000 E x I E x I x 1.73 Volts, Current 1000 1000 kW x 1000 kW x 1000 AMPERES kW, Volts, Power Factor...

  • Page 3: Table Of Contents

    Contents Overspeed Shutdown ........23 SPECIFICATIONS............. 4 RPM Sensor Failure .........23 Generator ..............4 Overcrank Shutdown ........24 Stator Winding Resistance Values/ 1.6 Operating Instructions ........25 Rotor Resistance ............. 4 Control Panel ...........25 Engine ..............5 To Select Automatic Operation ......26 Fuel Consumption ...........
  • Page 4 Test 12 - Check And Adjust Engine Governor Test 24 - Check Manual Transfer (Single Cylinder Units) ......46 Switch Operation .........68 Test 12A - Check Stepper Motor Control Test 25 - Test Limit Switch XB1 ......69 (V-twin Engine Units) ......46 Test 26 - Check 23 And 194 Test 13 - Check And Adjust Wiring/Connections ......69...
  • Page 5 Problem 15 - Generator Starts Test 70 - Check Wire 18 Continuity ....123 Immediately in Auto - No Transfer to Test 71 - Check N1 And N2 Voltage ....123 Standby. Utility Voltage is Present ..101 Test 72 - Check Utility Sensing Voltage Problem 16 - 15 Amp Fuse (F1) Blown ..102 At The Circuit Board ......124 Problem 17 - Generator Will Not Exercise ..102...

  • Page 6: Specifications

    SPECIFICATIONS GENERATOR Model 005243 & 005283 005240 & 005280 005241 & 005281 005242 & 005282 005244 & 005284 Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP Rated Voltage 120/240 120/240 120/240 120/240 Rated Max.

  • Page 7: Engine

    SPECIFICATIONS ENGINE 005243 & 005283 Model 005240 & 005280 005241 & 005281 005242 & 005282 005244 & 005284 Type of Engine GH-410 GT-530 GT-990 GT-990 Number of Cylinders Rated Horsepower 14.5 @ 3,600 rpm 18 @ 3,600 rpm 30 @ 3,600 rpm 30 @ 3,600 rpm Displacement 410cc...

  • Page 8: Mounting Dimensions

    SPECIFICATIONS MOUNTING DIMENSIONS Page 6...
  • Page 9 SPECIFICATIONS MOUNTING DIMENSIONS Page 7...

  • Page 10: Major Features

    SPECIFICATIONS MAJOR FEATURES 7 kW, Single Cylinder GH-410 Engine 10 kW, V-twin GT-530 Engine Control Control Panel Panel Data Data Air Filter Decal Dipstick Dipstick Decal Cover Exhaust Exhaust Enclosure Air Filter Enclosure Fuel Fuel Inlet Inlet (Back) (Back) Fuel Fuel Regulator Regulator...

  • Page 11: Part 1 - General Information

    TABLE OF CONTENTS PART TITLE PAGE Generator Identification Prepackaged Installation PART 1 Basics GENERAL Preparation Before Use Testing, Cleaning and Drying INFORMATION Engine-Generator Protective Devices Operating Instructions Automatic Operating Parameters Air-cooled, Prepackaged Automatic Standby Generators 1.1 Generator Identification ........10 Visual Inspection ..........20 1.2 Prepackaged Installation Basics .....

  • Page 12: Generator Identification

    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- 0055555 sonnel with the testing, troubleshooting and repair of Item # air-cooled, prepackaged automatic standby genera- tors.

  • Page 13: Prepackaged Installation Basics

    SECTION 1.2 PART 1 GENERAL INFORMATION PREPACKAGED INSTALLATION BASICS INTRODUCTION LP (propane) gas is usually supplied as a liquid in pressure tanks. Both the air-cooled and the liquid Information in this section is provided so that the ser- cooled units require a “vapor withdrawal” type of fuel vice technician will have a basic knowledge of instal- supply system when LP (propane) gas is used.
  • Page 14 SECTION 1.2 PART 1 GENERAL INFORMATION PREPACKAGED INSTALLATION BASICS Figure 1. Typical Prepackaged Installation Page 12...

  • Page 15: Power Source And Load Lines

    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 (genera- Prepackaged home standby generators are equipped tor) supply lines, and electrical load lines must all be with a terminal board identified with the following ter- connected to the proper terminal lugs in the transfer minals: (a) UTILITY 1, (b) UTILITY 2, (c) 23, and (d)

  • Page 16: Preparation Before Use

    SECTION 1.3 PART 1 GENERAL INFORMATION PREPARATION BEFORE USE GENERAL All installed gaseous fuel piping must be purged and leak tested prior to initial start-up in accordance with local codes, standards and regulations. The installer must ensure that the home standby gen- erator has been properly installed.
  • Page 17 SECTION 1.3 PART 1 GENERAL INFORMATION PREPARATION BEFORE USE 7. Remove the square headed steel pipe plug from out- 12.Check for gas leakage at the pipe plug, hose connection let port #1 and the brass hose barb fitting from outlet and fittings.

  • Page 18: Engine Oil Recommendations

    SECTION 1.3 PART 1 GENERAL INFORMATION PREPARATION BEFORE USE • Slide the selector lever out towards the back of the ENGINE OIL RECOMMENDATIONS enclosure (Figures 5 and 6). The primary recommended oil for units with air- • Return the air cleaner cover and tighten the two cooled, single cylinder or V-Twin engines is synthetic thumb screws.

  • Page 19: Testing, Cleaning And Drying

    SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING METERS MEASURING AC VOLTAGE Devices used to measure electrical properties are An accurate AC voltmeter or a VOM may be used to called meters. Meters are available that allow one read the generator's AC output voltage.

  • Page 20: Measuring Current

    SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING Correct engine and Rotor speed is maintained by an NOTE: If the physical size of the conductor or engine speed governor. For models rated 60 Hertz, ammeter capacity does not permit all lines to be the governor is generally set to maintain a no-load fre- measured simultaneously, measure current flow quency of about 62 Hertz with a corresponding output...

  • Page 21: Electrical Units

    SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING Component testing may require a specific resis- OHM: tance value or a test for INFINITY or CONTINUITY. The OHM is the unit of RESISTANCE. In every circuit Infinity is an OPEN condition between two electrical there is a natural resistance or opposition to the flow points, which would read as no resistance on a VOM.

  • Page 22: Visual Inspection

    SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING VISUAL INSPECTION Use a megger power setting of 500 volts. Connect one megger test lead to the junction of all stator leads, the other test lead to frame ground on the sta- When it becomes necessary to test or troubleshoot a tor can.

  • Page 23: Stator Insulation Resistance Test

    SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING selector switch that permits the power supply voltage c. Turn the tester switch ON and observe the to be selected. It also mounts a breakdown lamp that breakdown lamp on tester. DO NOT APPLY will illuminate to indicate an insulation breakdown dur- VOLTAGE LONGER THAN 1 SECOND.

  • Page 24: Rotor Insulation Resistance Test

    SECTION 1.4 PART 1 GENERAL INFORMATION TESTING, CLEANING AND DRYING 4. 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”...

  • Page 25: Engine-Generator Protective Devices

    SECTION 1.5 PART 1 GENERAL INFORMATION ENGINE-GENERATOR PROTECTIVE DEVICES GENERAL OVERSPEED SHUTDOWN Standby electric power generators will often run During engine cranking and operation, the circuit unattended for long periods of time. Such operating board receives AC voltage and frequency signals from parameters as (a) battery voltage, (b) engine oil pres- the ignition magneto, via Wire 18.

  • Page 26: Overcrank Shutdown

    SECTION 1.5 PART 1 GENERAL INFORMATION ENGINE-GENERATOR PROTECTIVE DEVICES OVERCRANK SHUTDOWN This feature prevents the generator from damaging itself when it continually attempts to start and another problem, such as no fuel supply, prevents it from start- ing. The unit will crank and rest for a preset time limit. Then, it will stop cranking, and the LED on the gen- erator control panel will light indicating an overcrank failure.

  • Page 27: Operating Instructions

    SECTION 1.6 PART 1 GENERAL INFORMATION OPERATING INSTRUCTIONS CONTROL PANEL ANY TIME WITHOUT WARNING (PROVIDING THE AUTO-OFF-MANUAL SWITCH IS SET TO AUTO). TO PREVENT AUTOMATIC STARTUP GENERAL: AND POSSIBLE INJURY THAT MIGHT BE See Figure 1 for control panel configurations. CAUSED BY SUCH STARTUP, ALWAYS SET THE AUTO-OFF-MANUAL SWITCH TO ITS OFF POSITION BEFORE WORKING ON OR...

  • Page 28: To Select Automatic Operation

    SECTION 1.6 PART 1 GENERAL INFORMATION OPERATING INSTRUCTIONS This DIP switch position is only read at board power To select automatic operation when a prepackaged up. If the DIP switch position is changed, power to the transfer switch is installed along with a prepackaged board must be cycled for the micro controller to recog- home standby generator, proceed as follows: nize the new DIP switch position.

  • Page 29: Manual Shutdown And Retransfer

    SECTION 1.6 PART 1 GENERAL INFORMATION OPERATING INSTRUCTIONS MANUAL SHUTDOWN AND RETRANSFER BACK TO “UTILITY” To shut the generator down and retransfer electrical loads back to the UTILITY position, proceed as fol- lows: 1. Set the generator main line circuit breaker to its OFF or “Open”...

  • Page 30: Automatic Operating Parameters

    SECTION 1.7 PART 1 GENERAL INFORMATION AUTOMATIC OPERATING PARAMETERS INTRODUCTION A. Utility Voltage Dropout Sensor • This sensor monitors utility source voltage. When the prepackaged generator is installed in conjunction with a prepackaged transfer switch, • If utility source voltage drops below about 65 percent either manual or automatic operation is possible.

  • Page 31: Part 2 - Ac Generators

    TABLE OF CONTENTS PART TITLE PAGE# 2.1. Description and Components Operational Analysis PART 2 Troubleshooting Flow Charts Diagnostic Tests AC GENERATORS Air-cooled, Prepackaged Automatic Standby Generators 2.1 Description and Components ......30 Test 1 - Check Main Circuit Breaker....39 Introduction ............30 Test 2 - Check AC Output Voltage ....39 Engine-generator Drive System .......30 Test 4 - Fixed Excitation Test/Rotor...

  • Page 32: Description And Components

    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 generator rotor are driven at approximately 3600 rpm, The air-cooled, pre-packaged automatic standby sys- to provide a 60 Hz AC output.

  • Page 33: Stator Assembly

    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 34 SECTION 2.1 PART 2 AC GENERATORS DESCRIPTION & COMPONENTS Figure 5. Typical Voltage Regulator A single red lamp (LED) glows during normal opera- tion. The lamp will become dim if excitation winding AC output diminishes. It will go out on occurrence of an open condition in the sensing AC output circuit.

  • Page 35: 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 36: Operation

    SECTION 2.2 PART 2 AC GENERATORS OPERATIONAL ANALYSIS OPERATION The greater the current flow through the rotor wind- ings, the more concentrated the lines of flux around the rotor become. STARTUP: The more concentrated the lines of flux around the When the engine is started, residual plus field boost rotor that cut across the stationary stator windings, magnetism from the rotor induces a voltage into (a)

  • Page 37: 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 identify the problem. Once that has been done, locate the flow charts correspond to the numbered tests in the problem on the following pages.
  • Page 38 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 TEST 10 - GOOD TEST ROTOR ASSEMBLY PERFORM STATOR GOOD...

  • Page 39: Problem 2 - Generator Produces Low Voltage At No-Load

    SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS Problem 2 - Generator Produces Low Voltage at No-Load LOW - TEST 12 - ADJUST SINGLE CYLINDER ENGINE GOVERNOR TEST 2 - CHECK TEST 11 - CHECK UNITS AC OUTPUT AC OUTPUT VOLTAGE FREQUENCY TEST 12A - CHECK...

  • Page 40: Problem 4 - Voltage And Frequency Drop Excessively When Loads Are Applied

    SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS Problem 4 - Voltage and Frequency Drop Excessively When Loads Are Applied IF RECONFIGURED TO LP GAS, TEST 14 - CHECK TEST 15 - CHECK VERIFY THAT PROPER BOTH VOLTAGE AND FOR OVERLAOD OVERLOADED PROCEDURE WAS FOLLOWED FREQUENCY...

  • Page 41: Diagnostic Tests

    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 test- ing and evaluation of various problems that could be the main circuit breaker terminals, to prevent interaction.

  • Page 42: Test 4 - Fixed Excitation Test/Rotor

    SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS ning, this should create a proportional voltage output DANGER: USE EXTREME CAUTION from the stator windings. DURING THIS TEST. THE GENERATOR WILL BE RUNNING. HIGH AND DANGEROUS PROCEDURE: VOLTAGES WILL BE PRESENT AT THE 1.

  • Page 43: Test 5: Wire Continuity

    Wire 4 to the voltage regulator. RESULTS: Refer to the chart on this page: “Results - Fixed Excitation Test/Rotor Amp Draw Test”. EXAMPLE: MODEL 5240 WIRE 2 & 6 VOLTAGE 87 VAC WIRE 11 & 22 VOLTAGE 31 VAC STATIC ROTOR AMP DRAW 1.0 AMP...

  • Page 44: Test 6 - Check Field Boost

    SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS TEST 6 - CHECK FIELD BOOST RESULTS: 1. If normal field boost voltage is indicated in Step 6, replace the voltage regulator. DISCUSSION: See “Field Boost Circuit” in Section 2.2. Field boost 2.
  • Page 45 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS from each other and are not touching the frame during 11.Connect on test lead to Pin 5. Connect the other test the test. lead to Pin 6 (excitation winding). Note the resistance reading, compare to specifications in the front of this 5.

  • Page 46: Test 8 - Resistance Check Of Rotor Circuit

    SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS RESULTS: out or fail. However, slip rings can develop a tarnish or film that can inhibit or offer a resistance to the flow of 1. Stator winding resistance values is a test of winding electricity.

  • Page 47: Test 10 - Test Rotor Assembly

    SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS 7. Connect one meter test lead to Wire 4 Connect the tive (+) rotor slip ring (nearest the rotor bearing); and other meter test lead to frame ground. INFINITY should the common (-) test lead to the negative (-) slip ring. be measured.

  • Page 48: Test 12 - Check And Adjust Engine Governor (Single Cylinder Units)

    SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS 2. Start the engine, let it stabilize and warm up at no-load. PROCEDURE (7 KW UNITS WITH DUAL GOVERNOR SPRINGS): 3. When engine has stabilized, read the frequency meter. 1. Loosen the governor clamp bolt (Figure 8). The no-load frequency for single cylinder units should be about 62-63 Hertz.
  • Page 49 SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS 4. If no movement is seen in Step 3 remove the control c. Connect one meter lead to Red, connect the remaining test lead to Brown, approximately 10 panel cover. Verify the six pin connector on the printed ohms should be measured.

  • Page 50: Voltage Regulator

    SECTION 2.4 PART 2 AC GENERATORS DIAGNOSTIC TESTS TEST 13 - CHECK AND ADJUST VOLTAGE PROCEDURE: REGULATOR 1. Connect an accurate AC frequency meter and an AC voltmeter across the stator AC power winding leads. DISCUSSION: 2. Start the engine, let it stabilize and warm-up. For additional information, refer to description and components Section 2.1.

  • Page 51: Transfer Switches

    TABLE OF CONTENTS PART 3 PART TITLE 3.1. Description and Components “V-TYPE” Operational Analysis Troubleshooting Flow Charts PREPACKAGED Diagnostic Tests TRANSFER SWITCHES Air-cooled, Prepackaged Automatic Standby Generators 3.1 Description and Components ......50 3.4 Diagnostic Tests ..........66 General ............50 General ............66 Enclosure ............50 Test 21 - Check Voltage at...

  • Page 52: Description And Components

    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 usable “National Electrical Manufacturer’s Association”).

  • Page 53: Transfer Mechanism

    SECTION 3.1 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DESCRIPTION & COMPONENTS source side. Energizing the coil moves the load con- TRANSFER MECHANISM tacts to an overcenter position; limit switch action then opens the circuit and spring force will complete the The 2-pole transfer mechanism consists of a pair transfer action to “Standby”.

  • Page 54: Neutral Lug

    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- tacts are closed. The standby generator is equipped with an UNGROUNDED neutral. The neutral lug in the trans- d.

  • Page 55: Fuse Holder

    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 56: Operational Analysis

    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. 12Vdc TRANSER COIL TS TO OPEN GENERATOR CONTROL PANEL 240VAC OUTPUT BLACK TO GENERATOR OUTPUT CIRCUIT BREAKER NEUTRAL (WHITE) NEUTRAL CONNECTION...
  • Page 57 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 55...

  • Page 58: 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 59: 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 60: 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 61: Transfer To Standby

    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 62: 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 63: Utility Restored, Transfer Switch De-Energized

    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 64: Utility Restored, Retransfer Back To Utility

    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 65: 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 66: Troubleshooting Flow Charts

    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 67: No Retransfer To Utility Power

    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 68: Diagnostic Tests

    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 69: Test 23 - Test Transfer Relay Tr

    SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS e. Set the generator AUTO-OFF-MANUAL switch VOLTAGE TEST WHILE STANDING ON WET to AUTO. OR DAMP GROUND, WHILE BAREFOOT, OR WHILE HANDS OR FEET ARE WET. (1) The generator should crank and start. (2) When the generator starts, an “engine 4.

  • Page 70: Test 24- Check Manual Transfer

    SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS RESULTS: DESIRED METER READING CONNECT VOM TEST 1. Replace transfer relay if it is defective. 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 71: Test 25- Test Limit Switch Xb1

    SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS OFF. FAILURE TO TURN OFF ALL POWER 3. See Figure 1. Connect the VOM test probes across VOLTAGE SUPPLIES MAY RESULT IN the two outer terminals from which the wires were EXTREMELY HAZARDOUS AND POSSIBLY disconnected.

  • Page 72: Test 27- Check Voltage At Terminal Lugs N1, N2

    SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS a. If voltage is present, proceed to Step 7. IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK. DO NOT ATTEMPT b. If voltage is not present, repair wiring between THIS TEST WHILE STANDING ON WET OR transfer switch and generator control panel.

  • Page 73: Test 30 - Check Fuses F1 And F2

    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 74: Test 31 - Test Limit Switch Xa1

    SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS NOTE: Problems with transfer switch opera- tion can also be caused by (a) defective wiring between the generator and transfer switch, or (b) a defective component in the generator circuit board.

  • Page 75: Test 34 - Check N1 And N2 Wiring

    SECTION 3.4 “V-TYPE” PREPACKAGED PART 3 TRANSFER SWITCHES DIAGNOSTIC TESTS 7. Disconnect Wire E1 from Transfer Relay (TR) Terminal 9. Connect one test lead to Wire N2 removed in Step 7, 9 and connect one test lead to it. Connect the other and the other test lead to the ground terminal.
  • Page 76 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 should For Steps 5, 6, and 7, replace transformer if an open is indicated, or if the resistance value indicated is be measured.

  • Page 77: Part 4 - Dc Control

    TABLE OF CONTENTS PART TITLE PAGE# 4.1. Description and Components Operational Analysis PART 4 Troubleshooting Flow Charts DC CONTROL Diagnostic Tests Air-cooled, Prepackaged Automatic Standby Generators 4.1 Description and Components ..........76 Test 48 - Test Starter Contactor Relay General 76 (V-twin Only)............

  • Page 78: Description And Components

    SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS GENERAL a reduced voltage (about 12 to 16 volts) into both secondary transformer windings. Reduced voltage from one secondary winding is delivered to the circuit This section will familiarize the reader with the various board as “Utility”...
  • Page 79 SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS CUSTOMER CONNECTIONS (TS) GROUND TERMINAL NEUTRAL BLOCK TRANSFORMER (TX) IDLE CONTROL TRANSFORMER (ICT) (V-TWINS ONLY) VOLTAGE STARTER REGULATOR CONTACTOR RELAY (SCR) (V-TWINS ONLY) BATTERY CHARGER BATTERY CHARGE RELAY (BCR) 4-TAB TERMINAL GROUND BLOCK (TB) TERMINAL...
  • Page 80 SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS OVERCRANK OVERSPEED J1 CONNECTOR HARNESS END HI OIL TEMPERATURE LOW OIL PRESSURE LOW BATTERY SYSTEM READY DIPSWITCH 1 ON = NORMAL EXERCISE 16 kW UNITS ONLY OFF = LOW SPEED EXERCISE DIPSWITCH 2 SPARE Figure 4.
  • Page 81 SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS OVERCRANK OVERSPEED HI OIL TEMPERATURE LOW OIL PRESSURE LOW BATTERY J1 CONNECTOR HARNESS END SYSTEM READY Figure 5. 7 kW Printed Circuit Board and J1 Connector 7 kW J1 Connector Pin Descriptions WIRE CIRCUIT FUNCTION WIRE...

  • Page 82: Auto-Off-Manual Switch

    SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS AUTO-OFF-MANUAL SWITCH 15 AMP FUSE This 3-position switch permits the operator to (a) This fuse protects the circuit board against excessive select fully automatic operation, (b) start the genera- current. If the fuse has blown, engine cranking and tor manually, or (c) stop the engine and prevent auto- operation will not be possible.
  • Page 83 SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS BACK PANEL C1 CONNECTOR C2 CONNECTOR C3 CONNECTOR FEMALE SIDE MALE SIDE Figure 8. C1, C2 & C3 Connector Locations and Pin Number Identification Page 81...

  • Page 84: Operational Analysis

    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 con- trol system on prepackaged units with air-cooled engine. A thorough understanding of how the system works is essential to sound and logical troubleshooting.
  • Page 85 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 contacts at their “Utility” side, this source voltage is available to Terminal Lugs T1/T2 and to the “Load” circuits. •...

  • Page 86: 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, below. 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 87 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • Should utility voltage drop below approximately 65 percent of the nominal source voltage, a 10-second timer on the circuit board will turn on. • In Figure 2, the 10-second timer is still timing and engine cranking has not yet begun. •...

  • Page 88: Engine Cranking

    SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS UTILITY VOLTAGE DROPOUT AND ENGINE CRANKING • After ten (10) seconds and when the circuit board’s 10-second timer has timed out, if utility voltage is still below 65 percent of nominal, circuit board action will energize the circuit board’s crank and run relays simultaneously. •...
  • Page 89 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • Printed circuit board action delivers 12 volts DC to the fuel solenoids (FS1 & FS2), via Wire 14. The fuel sole- noids energize open and fuel is available to the engine. Wire 14 energizes the battery charge relay (BCR), which will allow the BCR to power the battery charger.

  • Page 90: Engine Startup And Running

    SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS ENGINE STARTUP AND RUNNING With the fuel solenoids open and ignition occurring, the engine starts. Engine startup and running may be briefly described as follows: • Voltage pulses from the ignition magnetos are delivered to the circuit board via Wire 18. Once the circuit board determines that the engine is running, the circuit board (a) terminates cranking, and (b) terminates the choke solenoid (CS), and (c) turns on an “engine warm-up timer”.
  • Page 91 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • The “engine warm-up timer” will run for about 5 seconds. When this timer finishes timing, board action will initi- ate transfer to the STANDBY power source. As shown in Figure 4 (below), the timer is still running and transfer has not yet occurred.

  • Page 92: Initial Transfer To The "Standby" Source

    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 93 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • 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. The standby closing coil energizes and the main current carrying contacts of the transfer switch are actuated to their STANDBY source side.

  • Page 94: Utility Voltage Restored / Re-Transfer To Utility

    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 95 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 posi- tion. The main contacts move to an over center position past NEUTRAL and spring force closes them to their UTILITY side.

  • Page 96: 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.
  • Page 97 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • 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. • Circuit board action will connect the engine’s ignition magnetos (IM1 & IM2) to ground, via Wire 18. Ignition will be terminated.

  • Page 98: Troubleshooting Flow Charts

    SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 8 - Engine Will Not Crank When Utility Power Source Fails VERIFY UTILITY TEST 41 - CHECK SOURCE IS “OFF” SWITCH IS TEST 42 - TRY A POSITION OF SYSTEM READY IN “AUTO”...

  • Page 99: Problem 10 - Engine Cranks But Won't Start

    SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 10 - Engine Cranks but Won’t Start SINGLE CYLINDER UNITS TEST 51 - CHECK TEST 52 - CHECK TEST 53 - CHECK GOOD GOOD FUEL SUPPLY CIRCUIT BOARD FUEL SOLENOID V-TWIN UNITS AND PRESSURE WIRE 14 OUTPUT...

  • Page 100: Problem 11 - Engine Starts Hard And Runs Rough / Lacks Power

    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 51 - CHECK CHECK AIR FILTER - VERIFY THAT PROPER FUEL SUPPLY GOOD GOOD REPLACE AS NEEDED PROCEDURE WAS FOLLOWED.

  • Page 101: Problem 12 - Engine Starts And Runs, Then Shuts Down

    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 REFILL, REPAIR OR PRESSURE SWITCH LOW OIL ILLUMINATED REPLACE AND WIRE 86 TEST 61 - CHECK HIGH CHECK INSTALLATION FOR OIL TEMPERATURE OVER TEMP...

  • Page 102: Problem 13 - No Battery Charge

    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 66 - CHECK AC TEST 67 - TEST TEST 65 - TEST GOOD...

  • Page 103: Problem 14 - Unit Starts And Transfer Occurs When Utility Power Is Available

    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 REPLACE TEST 71 - TEST 72 - CHECK TRANSFORMER (TX) GOOD GOOD CIRCUIT CHECK N1 & N2 GOOD UTILITY SENSING VOLTAGE OUTPUT...

  • Page 104: Problem 16 - 15 Amp Fuse (F1) Blown

    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” CRANKING AND OR “MANUAL”...

  • Page 105: Diagnostic Tests

    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 section are not exhaustive.

  • Page 106: Test 44 - Check Wire 15/15A/15B/239/0

    SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS PROCEDURE: TEST 44 - CHECK WIRE 15/15A/15B/239/0 Disconnect all wires from switch terminals, to prevent VOLTAGE interaction. Then, use a volt-ohm-milliammeter (VOM) DISCUSSION: to test for continuity across switch terminals as shown The circuit board will not turn on unless battery volt- in the following chart.

  • Page 107: Test 45 - Check 15 Amp Fuse

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS cise switch (SW2). If battery voltage is measured TEST 46- CHECK BATTERY repair or replace Wire 15B between SW2 and The J1 Connector. If battery voltage is not mea- DISCUSSION: sured connect the positive meter test lead to Battery power is used to (a) crank the engine and Wire 15 at SW2.

  • Page 108: Test 47 - Check Wire 56 Voltage

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 47 - CHECK WIRE 56 VOLTAGE DISCUSSION: During an automatic start or when starting manually, a crank relay on the circuit board should energize. Each time the crank relay energizes, the circuit board should deliver 12 volts DC to a starter contactor relay (SCR), or starter contactor (SC), and the engine should crank.

  • Page 109: Test 50 - Test Starter Motor

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS or corroded, remove the cable and clean cable ter- 2. If battery voltage was indicated in Step 2b, but the minals and terminal studs. Replace any cable that is engine did NOT crank, go on to Test 50. defective or badly corroded.
  • Page 110 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS PINION Figure 6. Starter Motor (V-Twin Engines) Figure 9. 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: •...

  • Page 111: Test 51 - Check Fuel Supply

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS CLAMP ON AMP METER STARTER CONTACTOR Figure 11. Tachometer STARTER MOTOR TEST BRACKET: A starter motor test bracket may be made as shown in Figure 12. A growler or armature tester is available from an automobile diagnostic service supplier.

  • Page 112: Test 52 - Check Circuit Board

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS (PROPANE) GAS IS HEAVIER THAN AIR, TENDS TO SETTLE IN LOW AREAS. EVEN PRESSURE THE SLIGHTEST SPARK CAN IGNITE THESE GASES AND CAUSE AN EXPLOSION. PROCEDURE: A water manometer or a gauge that is calibrated in “ounces per square inch”...

  • Page 113: Test 53 - Check Fuel Solenoid

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS RESULTS Refer to flow chart. TEST 53 - CHECK FUEL SOLENOID DISCUSSION: In Test 52, if battery voltage was delivered to Wire 14, the fuel solenoid should have energized open. This test will verify whether or not the fuel solenoid is operating.

  • Page 114: Test 54- Check Choke Solenoid

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS sured. If gas pressure is measured then fuel solenoid TEST 54- CHECK CHOKE SOLENOID (FS1) is operating, replace FS2. If gas pressure is not (V-TWINS UNITS ONLY) measured repair or replace fuel solenoid (FS1). DISCUSSION: RESULTS: The automatic choke is active cyclically during crank-...

  • Page 115: Test 55 - Check For Ignition Spark

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 4. With the generator running at speed approximately 57.5- 59.5 Hertz. Verify the choke is energized and holding the CHOKE SOLENOID choke plate open. Repeat Step 2 procedure, however once it starts, manually hold choke open while making voltage measurement.

  • Page 116: Test 56 - Check Spark Plugs

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 56 - CHECK SPARK PLUGS SPARK TESTER DISCUSSION: CLAMP If the engine will not start and Test 55 indicated good ignition spark, perhaps the spark plug(s) are fouled or otherwise damaged. Engine miss may also be caused by defective spark plug(s).

  • Page 117: Test 58 - Check Shutdown Wire

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS DISCUSSION: PROCEDURE: The Cylinder Leak Down Tester checks the sealing 1. Remove both spark plugs. (compression) ability of the engine by measuring air 2. Insert a compression gauge into either cylinder. leakage from the combustion chamber. Compression loss can present many different symptoms.

  • Page 118: Test 59 - Check And Adjust

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS a. On V-twin units, remove Wire 56 from the Starter RESULTS: Contactor Relay (SCR). Using a jumper lead, 1. If INFINITY was NOT measured in Step 4, repair jump 12 VDC from Wire 15 at Fuse (F1) to the or replace shorted ground Wire 18 between the J1 terminal on the SCR that Wire 56 was removed Connector from the circuit board to the stud or bullet...

  • Page 119: Test 60- Check Oil Pressure Switch

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 5. To remove the thickness gauge, rotate the flywheel. RESULTS: If sparking still does not occur after adjusting the 6. Repeat the above procedure for the second magneto. armature air gap, testing the ground wires and per- forming the basic flywheel test, replace the ignition 7.

  • Page 120: Test 61 - Check High Oil

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS c. Note the oil pressure. RESULTS: 1. Replace switch if it fails the test. (1) Normal oil pressure is approximately 35-40 psi with engine running. If normal oil pres- sure is indicated, go to Step 4 of this test. TEST 61- CHECK HIGH OIL TEMPERATURE (2) If oil pressure is below about 4.5 psi, shut engine down immediately.

  • Page 121: Test 62 - Check And Adjust Valves

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS BALL STUD JAM NUT 0.076 mm (0.003") SHIM Figure 35 Figure 34. Testing the Oil Temperature Switch 5. Re-install the rocker cover gasket, rocker cover and the four (4) screws. RESULTS: 1. If the switch fails Step 4, or Steps 8-9, replace the RESULTS: switch.

  • Page 122: Test 64 - Check Battery Charge Output

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 4. When full load has been achieved, connect a frequency TEST 64 - CHECK BATTERY CHARGE meter to the output lugs of the generator main line cir- OUTPUT cuit breaker. a. The 7 kW fuel regulator is fitted with one adjust- DISCUSSION: ment screw.

  • Page 123: Battery Charger

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 66 - CHECK AC VOLTAGE AT BATTERY CHARGER DISCUSSION: The battery charger needs to be supplied with approx- imately 16 VAC. When the generator is not running 225A and utility source power is available, the battery char- ger still receives voltage from the Transformer (TX).

  • Page 124: Test 67 - Check Battery Charge Relay

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 67 - CHECK BATTERY CHARGE RELAY BCR Terminal “B”. Connect one test lead to Wire 0. Connect the other test lead to a clean frame (BCR) ground. CONTINUITY should be measured. If CONTINUITY was not measured, repair or replace Wire 0 between the BCR and the ground DISCUSSION:...

  • Page 125: Test 69 - Check Battery Charger Wiring

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 69 - CHECK BATTERY CHARGER WIRE 18 WIRING CONNECTION DISCUSSION: The three pin connector on the battery charger con- nects the charger to ground and to battery power. PROCEDURE: 1. Set the AUTO-OFF-MANUAL switch to OFF. 2.

  • Page 126: Test 72 - Check Utility Sensing Voltage

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 72 - CHECK UTILITY SENSING VOLTAGE AT THE CIRCUIT BOARD DISCUSSION: If the generator starts and transfer to STANDBY occurs in the automatic mode, even though an accept- able UTILITY source voltage is available from the Transformer (TX), the next step is to determine if that sensing voltage is reaching the circuit board.
  • Page 127 SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 3. Connect one meter test lead to the ground terminal. removed. Connect the other test lead to Wire 23 at the transfer switch terminal strip. If Connect the other meter test lead to each of the follow- CONTINUITY “ZERO RESISTANCE”...

  • Page 128: Test 77 - Test Exercise Function

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS TEST 77 - TEST EXERCISE FUNCTION Results: 1. If the generator still will not low speed exercise replace DISCUSSION: the printed circuit board. The following parameters must be met in order for the weekly exercise to occur: TEST 79 - CHECK IDLE CONTROL •...

  • Page 129: Test 81 - Check Idle Control Transformer

    SECTION 4.4 PART 4 DC CONTROL DIAGNOSTIC TESTS 4. Connect one meter test lead to Wire LC1 (red) at the In- TEST 81 - CHECK IDLE CONTROL Line Connector (IC). Connect the other meter test lead TRANSFORMER PRIMARY WIRING to Pin Location J1-8 on the J1 Connector previously removed.
  • Page 130 NOTES PART 4 DC CONTROL Page 128...

  • Page 131: Part 5 - Operational Tests

    TABLE OF CONTENTS PART TITLE 5.1. System Functional Tests PART 5 OPERATIONAL TESTS Air-cooled, Prepackaged Automatic Standby Generators Page 129...

  • Page 132: System Functional Tests

    SECTION 5.1 OPERATIONAL TESTS PART 5 AND ADJUSTMENTS SYSTEM FUNCTIONAL TESTS INTRODUCTION 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 133: Generator Tests Under Load

    SECTION 5.1 OPERATIONAL TESTS PART 5 AND ADJUSTMENTS SYSTEM FUNCTIONAL TESTS high or low, the engine governor requires adjust- DANGER ment. If frequency is correct, but voltage is high or low, the generator voltage regulator requires adjustment. THE TRANSFER SWITCH IS NOW ELECTRI- CALLY “HOT”, CONTACT WITH “HOT”...

  • Page 134: Checking Automatic Operation

    SECTION 5.1 OPERATIONAL TESTS PART 5 AND ADJUSTMENTS SYSTEM FUNCTIONAL TESTS With the generator running and loads powered by of abnormal operation. Check for oil leaks, evidence of generator AC output, turn ON the utility power supply overheating, etc. to the transfer switch. The following should occur: 12.When testing under load is complete, turn off electrical •...

  • Page 135: Part 6 - Disassembly

    TABLE OF CONTENTS PART TITLE 6.1. Major Disassembly Torque Specifications PART 6 DISASSEMBLY Air-cooled, Prepackaged Automatic Standby Generators Page 133...

  • Page 136: Major Disassembly

    SECTION 6.1 PART 6 DISASSEMBLY MAJOR DISASSEMBLY MAJOR DISASSEMBLY 7. Remove Muffler: Using a 10mm socket remove the eight bolts from the flex cover. Loosen the muffler pipe clamp closest to the engine exhaust manifold. Loosen STATOR/ROTOR/ENGINE REMOVAL: the exhaust clamp and remove the tailpipe. Remove four For stator removal, follow Steps 1-14.
  • Page 137 SECTION 6.1 PART 6 DISASSEMBLY MAJOR DISASSEMBLY Figure 3. Engine Adapter Supported by Piece of Wood Figure 5. Removing the Stator Using a 1/4” socket, remove Wire 0 and Wire 4 from the brush assembly. Remove the two brush assembly hold down bolts.

  • Page 138: Front Engine Access

    SECTION 6.1 PART 6 DISASSEMBLY MAJOR DISASSEMBLY FRONT ENGINE ACCESS. 4. Remove Intake manifolds: Using a 6mm allen wrench, remove the four (4) socket head cap screws from the 1. Follow Stator/Rotor/Engine removal procedures, intake manifolds. Remove the intake manifolds. Remove Steps 1-5.

  • Page 139: Part 7 - Electrical Data

    TABLE OF CONTENTS DWG# TITLE 0F7820 WIRING DIAGRAM, 7 KW HSB MODEL 005240 & 005280 PART 7 0F7821 SCHEMATIC, 7 KW HSB MODEL 005240 & 005280 ELECTRICAL 0F7822 WIRING DIAGRAM, 10, 13 & 16 KW HSB MODEL 005241 & 005281 MODEL 005242 &...

  • Page 140: Models 005240 & 005280

    WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 005240 & 005280 DRAWING #0F7820 DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB - MAIN OUTPUT BREAKER C1 - ENGINE HARNESS C2 - ALTERNATOR HARNESS FS - FUEL SOLENOID F1 - FUSE 15 AMP GRD 1 - GROUND CONNECTIONS IN CONTROL PANEL...
  • Page 141 WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 005240 & 005280 DRAWING #0F7820 CONTROL PANEL BOX 224A 225A CLOSEST TO BEARING 224A 225A 224B 225B STATOR 224B 225B VOLTAGE REGULATOR GRD 1 AUTO MANUAL 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR CUSTOMER CONNECTION...

  • Page 142: Drawing 0F7821 Wiring Schematic, 7 Kw Hsb Models 005240 & 005280

    SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 005240 & 005280 DRAWING #0F7821 BATTERY CHARGER 224B 225B 224B 225B ELECTRONIC VOLTAGE REGULATOR MANUAL AUTO 225B 224B CONTROL PRINTED CIRCUIT BOARD Page 140...
  • Page 143 SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 005240 & 005280 DRAWING #0F7821 ENGINE AND ALTERNATOR BATTERY CHARGE WINDING STATOR WINDING POWER POWER WINDING WINDING FIELD BATTERY 225B 224B 224A 225A NEUTRAL 224A 240VAC GENERATOR 12Vdc 240VAC 225A OUTPUT TO TRANSFER UTILITY...

  • Page 144: Models 005244 & 005284

    WIRING DIAGRAM, 12, 13 & 16 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 005241, 005242, 005243, 005244, 005281, 005282, & 005283, 005284 DRAWING #0F7822 DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB - MAIN OUTPUT BREAKER CS - IDLE CHOKE SOLENOID C1 - ENGINE HARNESS C2 - ALTERNATOR HARNESS...
  • Page 145 WIRING DIAGRAM, 12, 13 & 16 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 005241, 005242, 005243, 005244, 005281, 005282, & 005283, 005284 DRAWING #0F7822 CONTROL PANEL BOX 224A 225A 224A 225A CLOSEST TO BEARING 224B 225B STATOR 224B 225B VOLTAGE REGULATOR GRD 1...

  • Page 146: Models 005244 & 005284

    SCHEMATIC, 12, 13 & 16 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 005241, 005242, 005243, 005244, 005281, 005282, & 005283, 005284 DRAWING #0F7823 BATTERY CHARGER 224B 225B 224B 225B ELECTRONIC VOLTAGE REGULATOR GOVERNOR ACTUATOR MANUAL AUTO 225B 224B CONTROL PRINTED CIRCUIT BOARD Page 144...
  • Page 147 SCHEMATIC, 12, 13 & 16 KW HOME STANDBY PART 7 ELECTRICAL DATA MODELS 005241, 005242, 005243, 005244, 005281, 005282, & 005283, 005284 DRAWING #0F7823 ENGINE AND ALTERNATOR BATTERY CHARGE WINDING STATOR WINDING POWER POWER WINDING WINDING FIELD BATTERY I.C.T. 225B 224B 224A 225A...

  • Page 148: Circuit/16 Circuit

    WIRING DIAGRAM, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 8 THRU 16 CIRCUIT DRAWING #0F9070-A ALL CIRCUIT GROUNDED CONDUCTORS NOT SHOWN FOR CLARITY 16 CIRCUIT LOAD CENTER 12 CIRCUIT LOAD CENTER 10 CIRCUIT LOAD CENTER 8 CIRCUIT LOAD CENTER Page 146...

  • Page 149: Schematic

    WIRING DIAGRAM, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 8 THRU 16 CIRCUIT DRAWING #0F9070-A LEGEND ATS-AUTOMATIC TRANSFER SWITCH C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER F1,F2-5A, 600V FUSE LC-CIRCUIT BREAKER (LOADS) (16 CIRCUIT SHOWN FOR REFERENCE ONLY) N-NEUTRAL TR-TRANSFER RELAY TS-TERMINAL STRIP...
  • Page 150 SCHEMATIC, HOME STANDBY PART 7 ELECTRICAL DATA TRANSFER SWITCH, 8 THRU 16 CIRCUIT DRAWING #0F9775 12Vdc TRANSER COIL TS TO OPEN GENERATOR CONTROL PANEL 240VAC OUTPUT BLACK TO GENERATOR OUTPUT CIRCUIT BREAKER NEUTRAL (WHITE) NEUTRAL CONNECTION INSIDE SWITCH NEUTRAL (WHITE) 240VAC TO RED (MAIN 2) MAIN DISTRIBUTION...
  • Page 151 PO BOX 297 • WHITEWATER, WI 53190 www.guardiangenerators.com P/N 0G2152 REV. 0 Printed in the USA 6.06...

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