Related Manuals for Briggs & Stratton 040298
Summary of Contents for Briggs & Stratton 040298
- Page 1 Home Generator System Manual 278994GS Rev. - BRIGGS & STRATTON SERVICE & TROUBLESHOOTING MANUAL HOME GENERATOR SYSTEM - 7kW...
- Page 2 FORWARD This manual was written to assist technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton Home Standby Generators. It assumes that persons using this manual have been properly trained in and are familiar with the servicing procedures for these products, including the proper use of required tools and safety equipment and the application of appropriate safety practices.
- Page 3 SECTION 1 - Safety, Maintenance and Adjustments SECTION 2 - Troubleshooting SECTION 3 - Unit Disassembly SECTION 4 - Generator Specifications...
- Page 4 THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE, ECONOMICAL AND RELIABLE MODELS COVERED IN THIS MANUAL • 040298 • 040298A • 040301 • 040315 • 040320...
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Page 5: Equipment Description
SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS Equipment Description This product is intended for use as an optional residential generator system which provides an alternate source of WARNING Before attempting to service this electric power. This product does not qualify for emergency equipment, read and understand this manual and the standby as defined by NFPA 70 (NEC). - Page 6 WARNING Generators produce hazardous voltage. WARNING Battery posts, terminals, and related Failure to properly ground generator can result in accessories contain lead and lead compounds, chemicals electrocution. Failure to isolate generator from known to the State of California to cause cancer and utility power can result in death or injury to reproductive harm.
- Page 7 WARNING Propane and Natural Gas are extremely WARNING Starter and other rotating parts can flammable and explosive. Fire or explosion can entangle hands, hair, clothing, or accessories. cause severe burns or death. • NEVER operate generator without protective housings, covers, or guards in place. •...
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Page 8: Generator Clearances
Generator Clearances • DO NOT expose generator to excessive moisture, dust, dirt, lint, or corrosive vapors. Install generator outdoors in an area which will not • Remain alert at all times while working on this accumulate deadly exhaust gas. DO NOT install generator equipment. -
Page 9: Lifting The Generator
Lifting the Generator NOTICE: Laws or local codes may regulate the distance to the fuel supply. The generator weighs more than 350 pounds (159 kg). The minimum (MIN) clearances from aerial view of generator Proper tools, equipment, and qualified personnel should be (B) to combustible (D), and non-combustible (A) materials is used in all phases of handling and moving the generator. -
Page 10: Access To The Generator
Access To The Generator The 7kW Home Standby Generator System is equipped with several access openings and a removable roof (Figure 1). • Roof (A) • Access Door (B) • Side Panel (C) • Access Panel (D) • Access Cover for Oil Drain and Oil Filter (E) Each generator is supplied with a set of identical keys. - Page 11 To remove roof: Remove the four screws and lift off (A, Figure 2). Reinstall roof in the reverse order. WARNING Contact with the muffler area can result in serious burns. Exhaust heat/gases can ignite combustibles or structures causing a fire. •...
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Page 12: Generator Components
Generator Components Generator is shown with roof and access doors removed for clarity. — — F - Engine Label Identifies engine model, type, and code A - Lifting Pocket Provided at each corner for lifting numbers. generator. — — G - Oil Fill Cap/Dipstick Check and fill engine with B - Exhaust Port High-performance muffler lowers... - Page 13 System Controls — A - Set Exercise Used to set the exercise cycle start time — E - Manual Over-RIde This function allows the and day-of-the-week. Exercise cycle only occurs in AUTO technician to manually start and stop the generator. mode.
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Page 14: System Connections
System Connections Except for the power output and grounding connectors, all signal wire connections are made to removable two- or ten-pin connector plugs. Compare this illustration with your generator to familiarize yourself wtih the location of these important connections. Count down to the proper pin location on the control board since visual alignment with the decal can be misleading: —... -
Page 15: Fuel Factors
Fuel Factors An important consideration affecting the performance of the Natural Gas LP Vapor generator is the type of fuel used. The system was factory ½ Load Full Load ½ Load Full Load tested and adjusted using either natural gas or liquid propane 80 C 137 C 33 C... - Page 16 Figure 9 Figure 7 8. Locate the mixer (D). Figure 10 10. Using a common screwdriver, install supplied plug into upper chamber (G, Figure 10). 11. Reinstall brass cover (E). 12. Using Insertion Tool #19570, remove existing jet from lower carburetor inlet (H). 13.
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Page 17: Generator Ac Connection System
Generator AC Connection System Automatic Operation A single-phase, three-wire AC connection system is used in To select automatic operation, proceed as follows: this generator. The stator assembly consists of a pair of 1. Confirm 15 Amp fuse is installed. stationary windings with two leads brought out of each 2. -
Page 18: Setting Exercise Timer
Setting Exercise Timer Generator Maintenance The generator is equipped with an exercise timer that will Before performing any generator maintenance, always start and exercise the system once every seven days. During perform the following steps: this exercise period, the unit runs for approximately 20 1. -
Page 19: Replacing The Spark Plugs
Adjusting the Valve Lash Oil Service The valve lash must be checked every 100 hours of Checking the Oil Level operation. Measure valve clearance with the engine cold. Check the engine oil level as follows: To adjust the valve lash, proceed as follows: 1. -
Page 20: Servicing The Air Cleaner
Servicing the Air Cleaner The engine air cleaner is one of the most important areas to maintain. Use only genuine Briggs & Stratton parts which meet UL requirements for a generator. Clean the foam pre- cleaner (if equipped) every 25 hours and the filter cartridge every 100 hours of operation. -
Page 21: Engine Adjustment
4. Connect red battery cable to battery positive terminal, 7. Reinstall 15 Amp fuse in control panel. indicated by POSITIVE, POS, or (+). 5. Connect black battery cable to negative battery CAUTION With the system switch set to AUTO, the terminal, indicated by NEGATIVE, NEG, or (-). - Page 22 7. Normal no-load frequency is 62.0 to 62.5 Hz (3720 - 3750 RPM). If adjustment is needed at no-load, remove unit side panels. Using needle nose pliers or Tang Bender #19229 or #19480, bend spring anchor tang (A, Figure 12) slowly up or down until frequency is 62.0 to 62.5 Hz.
- Page 25 SECTION 2 - TROUBLESHOOTING Control Panel The control panel contains all the logic circuits, operator controls, and system displays necessary to operate, program, and protect the generator. The control panel interprets and monitors electrical inputs from all related circuits throughout the standby operation. Before replacing the control panel, all other circuits must be tested to ensure proper operation.
- Page 26 Figure 3 The control panel is connected to its various circuits through The functions of the 8-pin connector are shown below connectors that are mounted directly to the board (Figure 3), (Figure 4). shown tilted down. The 8-pin connector (A, Figure 3) is wired to the internal Vacant systems of the unit and is the primary point of measurement Vacant...
- Page 27 AUTOMATIC VOLTAGE REGULATOR (AVR) Accessing the Automatic Voltage Regulator The Automatic Voltage Regulator (AVR) (A, Figure 5) is • Voltage from the 120VAC stator power windings mounted inside the alternator air intake plenum (B). are available through wires 11, 12, 33, and 44 to the circuit breaker.
- Page 28 FAULT CODE (FC_X) INDICATIONS The control panel is equipped with sensing circuits that automatically shut down the generator in the event of potentially damaging conditions. When the control panel senses a condition that prevents the generator from functioning properly, it shuts down the generator and displays the fault code on the control panel.
- Page 30 (FC_1) LOW BATTERY VOLTAGE If the generator cannot start because the battery output TEST 2 - Check Trickle Charge Voltage at power is below that needed to crank the engine, the digital Battery display will show FC_1 and the remote LED will repeatedly 1.
- Page 31 Figure 8 • If approximately 13.5 VDC is not measured, Figure 9 proceed to TEST 3 - Check Utility Voltage Input. • If approximately 13.5 VDC is measured, proceed to Step 12. 12. Disconnect meter test leads. TEST 4 - Measure Trickle Charge Output 13.
- Page 32 • If no voltage is measured, replace the control panel. • If voltage is measure at the control panel, but not on Wire #13 at the battery connection, repair or replace the wiring between the control panel and the battery.
- Page 34 (FC_2) LOW OIL PRESSURE The Home Generator System is equipped with a Low Oil Pressure (LOP) switch. The contacts of the switch are normally closed, but are held open by oil pressure during engine operation. Should the engine oil pressure drop below a preset level, the contacts will close.
- Page 35 TEST 3 - Check Engine Oil Pressure 1. Remove the oil pressure switch and install a technician supplied oil pressure gauge. 2. Set control panel system switch to AUTO, then push and hold the MANUAL OVER-RIDE to start the unit. 3.
- Page 38 (FC_3) LOW VOLTAGE The low voltage shutdown feature is designed to protect the generator and its loads from an output voltage that is too TEST 2 - Measure Generator Voltage at low. When the generator has stabilized, the control panel control panel senses output voltage on Wires #E1 and #E2.
- Page 39 TEST 4 - Check Alternator There are two methods of testing the alternator windings: 1. Measuring the winding resistance and comparing them to the specifications. 2. Bypassing the Automatic Voltage Regulator (AVR). Either one can be used, or they can be used in conjunction with each other to confirm a diagnosis.
- Page 40 Check Rotor Resistance Through the Brush Wires In an effort to eliminate the need to disassemble the engine/ alternator assembly, the rotor resistance can be measured through the brush wires. This may, or may not provide conclusive results. Resistance measured through the brush wires will likely result in a slightly higher reading than the specifications listed in Section 4.
- Page 41 Bypass the AVR 4. Disconnect Wires #1, #4, #11A, #22A, #2, and #6 Bypassing the AVR will test all wiring and windings within the from the AVR. alternator without disassembly of the generator. There are 5. Set meter to measure AC Voltage. Connect one test two AC Voltage checks and one DC Amperage test to be lead to Wire #2 and the other lead to Wire #6 (Figure performed.
- Page 42 Figure 21 5. Disconnect the battery from Wire #1 and Wire #4. 6. Restore wiring connections to the circuit breaker and the AVR. 7. Analyze test results as follows: Figure 20 • If all readings are within the spec, the alternator is 11.
- Page 44 (FC_4) ENGINE DOES NOT START Whenever the unit is directed to start (MANUAL or AUTO), TEST 1 - Visually Inspect Generator the control panel delivers 12VDC from Pin #3, Wire #56 to 1. Remove all access doors to the unit. the starter contactor for 15 seconds.
- Page 45 Figure 23 Figure 22 4. Turn ON manual fuel valve. 3. Set control panel system switch to AUTO and push 5. Measure generator inlet fuel pressure. Fuel pressure MANUAL OVER-RIDE to start unit. should measure 7-11 in.wc (LP) or 5-7 in. wc (NG) •...
- Page 46 5. Remove the pipe plug in the regulator test port (A) 11. Measure DC volts while cranking. and install Briggs & Stratton Vacuum Tester #19495 • If no voltage is measured at the control panel, (Figure 25). replace the control panel. •...
- Page 48 Cranking Problems TEST 7 - Check Battery Components 1. Check the condition and electrical integrity of the battery and all wires, connectors, and cables throughout the unit. Some areas for particular focus are: • Battery state of charge • Battery connections •...
- Page 49 • If voltage is measured, repair or replace wiring between the control panel and the starter contactor. 2. Measure the voltage at the starter motor (B, Figure 31). The reading should be above 9.6VDC between the starter terminal and ground while cranking (the control panel will deliver 12VDC to the terminals of the starter contactor).
- Page 52 (FC_5) UNDER FREQUENCY Check No-Load Frequency The troubleshooting steps for under- and over- frequency faults are identical. 1. Remove the four screws to gain access to the main The low frequency shutdown feature is designed to circuit breaker. protect the generator and its loads from an output 2.
- Page 53 Check Full-Load Frequency TEST 2 - Measure Frequency at #E1 & #E2 1. With the unit running at full rated capacity, as 1. Turn OFF utility power to the transfer switch. The unit described in Check Full-Load Frequency, measure should start and transfer to generator power. the frequency at #E1 and #E2 at the control panel 2.
- Page 54 (FC_6) ENGINE OVERSPEED The control panel monitors generator output frequency at Wires #E1 and #E2. If the generator output frequency increases to 65Hz-70Hz, the control panel waits three seconds before shutting the unit down. Should the frequency exceed 70Hz, the control panel will shut down the generator immediately.
- Page 56 (FC_7) HIGH TEMPERATURE TEST 2 - Check Wire #95 The contacts of the Over-Temperature Switch (OTS) are normally open. If the engine oil reaches a critical 1. Gain access to the control panel. See How to Access temperature, the switch contacts will close and the control panel Board.
- Page 57 (FC_8) TRANSFER SWITCH FAILURE Transfer switch fault monitoring is an optional feature of the Home Generator System. A transfer switch with a compatible Air Conditioning Control Module (ACCM II or later) is required for this feature. This module monitors the transfer switch circuits during normal utility power and during standby power.
- Page 59 SECTION 3 - UNIT DISASSEMBLY Remove Access Door Remove Battery 1. Insert key into lock of access door handle and turn key one quarter-turn clockwise (Figure 1). WARNING Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
- Page 60 Remove the Exhaust Flex Tube 1. Remove the two bolts that hold the exhaust tube to the engine (A, Figure 4). Figure 6 2. Disconnect the line-side wiring (Figure 7) from the circuit breaker. Figure 4 2. Slip the flexible exhaust manifold up and out of the muffler assembly (B, Figure 5).
- Page 61 Disconnect Engine Wiring and Fuel Hose 1. Disconnect battery ground cable from engine block (A, Figure 9). Figure 12 Figure 9 5. Disconnect fuel supply hose at mixer, hose clamp (D, 2. Disconnect the wire (B, Figure 10) from the oil Figure 13), plug hose, and mixer inlet.
- Page 62 Engine / Alternator Removal WARNING Lifting Hazard / Heavy Object - Can cause muscle strain or back injury. • DO NOT lift or move generator without assistance. • DO NOT lift unit by roof as damage to the generator will occur. Depending on the type of lifting mechanism that you have available, it may be necessary to fabricate a pair of lifting eyes to remove the engine/alternator assembly from the...
- Page 63 Figure 21 WARNING Lifting Hazard / Heavy Object - Can cause Figure 19 muscle strain or back injury. WARNING Lifting Hazard / Heavy Object - Can cause • DO NOT lift or move generator without assistance. muscle strain or back injury. •...
- Page 64 Figure 23 Figure 26 2. Using a plastic, dead blow hammer, tap rear bearing carrier evenly over rotor bearing and stator until it seats. NOTICE: Do not use stator bolts to draw assembly together. 3. Insert stator bolts into each hole around the rear bearing carrier.
- Page 65 SECTION 4 - GENERATOR SPECIFICATIONS Models 040298, 040298A, 040301, 040315, 040320 Rated Maximum Power and Load Current (LP) at 240 Volts 29.1 Amps Rated AC Voltage 240 Volts Rated Frequency 60Hz Phase Single Phase Rated Temperature 77°F (25°C) Normal Operating Range -20°F to 104°F (-28.8°C to 40°C)