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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)
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TABLE OF CONTENTS PART TITLE Specifications 1 General Information DIAGNOSTIC 2 AC Generators 3 V-Type Prepackaged Transfer Switches REPAIR MANUAL 4 DC Control 5 Operational Tests and Adjustments 6 Disassembly 7 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)
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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 KVA Volts, Current E x I E x I x 1.73 1000 1000 AMPERES kW, Volts, Power Factor kW x 1000 kW x 1000 E E x 1.73 x PF WATTS Volts, Amps, Power Factor Volts x Amps E x I x 1.73 x PF NO. OF ROTOR Frequency, RPM 2 x 60 x Frequency 2 x 60 x frequency POLES RPM RPM FREQUENCY RPM, No. of Rotor Poles RPM x Poles RPM x Poles 2 x 60 2 x 60 RPM Frequency, No. of Rotor Poles
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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 25.0 NG/29.2 LP 50.0 NG/50.0 LP 54.2 NG/62.5 LP Main Line Circuit Breaker 30 Amp 50 Amp 60 Amp/70 Amp Phase 1 1 1 Number of Rotor Poles 2 2 2 Rated AC Frequen
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SPECIFICATIONS MOUNTING DIMENSIONS Page 3
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SPECIFICATIONS MOUNTING DIMENSIONS Page 4
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SPECIFICATIONS MAJOR FEATURES 7 kW, Single Cylinder GH-410 Engine 12 kW and 15 kW, V-twin GT-990 Engine Page 5
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TABLE OF CONTENTS PART TITLE 1.1 Generator Identification 1.2 Prepackaged Installation Basics PART 1 1.3 Preparation Before Use GENERAL 1.4 Testing, Cleaning and Drying 1.5 Engine-Generator Protective Devices INFORMATION 1.6 Operating Instructions 1.7 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)
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SECTION 1.1 GENERAL INFORMATION PART 1 GENERATOR IDENTIFICATION INTRODUCTION This Diagnostic Repair Manual has been prepared especially for the purpose of familiarizing service personnel with the testing, troubleshooting and repair of air-cooled, prepackaged automatic standby generators. Every effort has been expended to ensure that information and instructions in the manual are both accurate and current. However, Generac reserves the right to change, alter or otherwise improve the product at a
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SECTION 1.2 GENERAL INFORMATION PART 1 PREPACKAGED INSTALLATION BASICS The pressure at which LP gas is delivered to the INTRODUCTION generator fuel solenoid valve may vary considerably, depending on ambient temperatures. In cold weather, Information in this section is provided so that the supply pressures may drop to "zero". In warm service technician will have a basic knowledge of weather, extremely high gas pressures may be installation requirements for prepackaged home encountered. A primary
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SECTION 1.2 GENERAL INFORMATION PART 1 PREPACKAGED INSTALLATION BASICS Figure 1. Typical Prepackaged Installation Page 1.2-2
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SECTION 1.2 GENERAL INFORMATION PART 1 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 with a terminal board identified with the following connected to the proper terminal lugs in the transfer terminals: (a) UTILITY 1, (b) UTILITY 2, (c) 23, and (d) switch. The following rules apply:In 1-phas
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SECTION 1.3 GENERAL INFORMATION PART 1 PREPARATION BEFORE USE GENERAL ENGINE OIL RECOMMENDATIONS The installer must ensure that the home standby The primary recommended oil for units with air-cooled, generator has been properly installed. The system single cylinder or V-Twin engines is synthetic oil. must be inspected carefully following installation. All Synthetic oil provides easier starts in cold weather and applicable codes, standards and regulations maximum engine protection in hot weathe
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SECTION 1.4 GENERAL INFORMATION PART 1 TESTING, CLEANING AND DRYING VISUAL INSPECTION When it becomes necessary to test or troubleshoot a generator, it is a good practice to complete a thorough visual inspection. Remove the access covers and look closely for any obvious problems. Look for the following: ❏ Burned or broken wires, broken wire connectors, damaged mounting brackets, etc. ❏ Loose or frayed wiring insulation, loose or dirty connections. ❏ Check that all wiring is well clear of rotati
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SECTION 1.4 GENERAL INFORMATION PART 1 TESTING, CLEANING AND DRYING 2. Before reading a DC voltage, always set the meter to a higher voltage scale than the anticipated reading. if in doubt, start at the highest scale and adjust the scale downward until correct readings are obtained. 3. The design of some meters is based on the "current flow" theory while others are based on the "electron flow" theory. a. The "current flow" theory assumes that direct current flows from the positive (+) to the neg
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SECTION 1.4 GENERAL INFORMATION PART 1 TESTING, CLEANING AND DRYING If proper procedures are used, the following conditions can be detected using a VOM: ❏ A "short-to-ground" condition in any stator or rotor winding. ❏ Shorting together of any two parallel stator windings. ❏ Shorting together of any two isolated stator windings. ❏ An open condition in any stator or rotor winding. Component testing may require a specific resistance value or a test for INFINITY or CONTINUITY. INFINITY is an OPEN c
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SECTION 1.4 GENERAL INFORMATION PART 1 TESTING, CLEANING AND DRYING TESTING ROTOR INSULATION: INSULATION RESISTANCE Apply a voltage of 500 volts across the rotor positive The insulation resistance of stator and rotor windings (+) slip ring (nearest the rotor bearing), and a clean is a measurement of the integrity of the insulating frame ground (i.e. the rotor shaft). DO NOT EXCEED materials that separate the electrical windings from the 500 VOLTS AND DO NOT APPLY VOLTAGE generator steel core. T
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SECTION 1.4 GENERAL INFORMATION PART 1 TESTING, CLEANING AND DRYING TESTING ALL STATOR WINDINGS TO GROUND: 6. Now proceed to the C2 connector. Each winding will be individually tested for a short to ground. Insert a large 1. Disconnect stator output leads 11 and 44 from the paper clip (or similar item) into the C2 connector at the generator main line circuit breaker. following pin locations: 2. Remove stator output leads 22 and 33 from the neutral Pin Wire Winding connection and separate the two
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SECTION 1.4 GENERAL INFORMATION PART 1 TESTING, CLEANING AND DRYING 5. Insert a large paper clip into Pin Location No. 1 (Wire 6. Observe the breakdown lamp, then turn the tester 77). Connect the red tester probe to the paper clip. switch OFF. DO NOT APPLY VOLTAGE LONGER Connect the black tester probe to Stator Lead 33. Refer THAN ONE (1) SECOND. to Steps 5a through 5c of “TESTING ALL STATOR If the breakdown lamp came on during the one (1) WINDINGS TO GROUND” on the previous page. second test, c
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SECTION 1.5 GENERAL INFORMATION PART 1 ENGINE-GENERATOR PROTECTIVE DEVICES above. GENERAL Standby electric power generators will often run unattended for long periods of time. Such operating parameters as (a) engine oil pressure, (b) engine temperature, (c) engine operating speed, and (d) engine cranking and startup are not monitored by an operator during automatic operation. Because engine operation will not be monitored, the use of engine protective safety devices is required to prevent engine
