Related Manuals for Briggs & Stratton 076000NG
Summary of Contents for Briggs & Stratton 076000NG
- Page 1 Home Generator System Manual 278382GS Rev A 6/08 BRIGGS & STRATTON SERVICE & TROUBLESHOOTING MANUAL HOME GENERATOR SYSTEM - 30kW...
- Page 2 FORWARD This manual was written to assist authorized technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton home standby generator systems. 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS ........1 SAFETY MESSAGES ........................1 ACCESS TO THE GENERATOR....................5 GENERATOR COMPONENTS....................6 GENERATOR CLEARANCES ..................... 9 SYSTEM CONNECTIONS ......................10 FUEL SUPPLY ..........................12 ENGINE MAINTENANCE ......................13 SETTING THE EXERCISE TIMER .................... - Page 4 SECTION 3- SPECIFICATIONS & REFERENCE .............. 59 SPECIFICATIONS........................59 SCHEMATIC ..........................60 WIRING DIAGRAM ........................61 Page ii...
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Page 5: Section 1 - Safety, Maintenance And Adjustments
SECTION 1 - SAFETY, MAINTENANCE • Prior to work, read and understand the section(s) of this manual that pertain to AND ADJUSTMENTS the job. Follow all safety warnings. In The Interest Of Safety • Wear suitable eye protection. This repair manual contains safety information •... - Page 6 WARNING WARNING Generator produces hazardous volt- The engine exhaust from this product age. contains chemicals known to the State of California to cause cancer, birth defects, or Failure to properly ground generator other reproductive harm. can result in electrocution. WARNING Failure to isolate generator from power utility can result in death or Storage batteries give off explosive...
- Page 7 WARNING WARNING Propane and Natural Gas are Starter and other rotating parts can extremely flammable and explosive. entangle hands, hair, clothing, or accessories. Fire or explosion can cause severe burns or death. • NEVER operate generator without protec- • Install the fuel supply system according to tive housing or covers.
- Page 8 Standby Safety Practices • This manual contains important safety messages. Read these carefully and CAUTION understand them before proceeding with maintenance and repairs. Exceeding generators wattage/amperage capacity can damage generator and/or electri- • Become familiar with the Home cal devices connected to it. Generator System.
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Page 9: Access To The Generator
ACCESS TO THE GENERATOR Removing An Access Door 1. Insert key into lock of access door handle you wish to open and turn one quarter turn The home generator is equipped with an counterclockwise. Remove key. Handle will enclosure that has four access doors (Figure 1). remain unlocked until you relock it. -
Page 10: Generator Components
GENERATOR COMPONENTS needed to run the starter motor and also pro- NOTE: Generator is shown with access door removed. vided the force needed to engage the starter. A - Oil Dip Stick - Used to check the engine oil The starter is an electric motor used to turn over level. - Page 11 off the generator, and waits for the next utility power outage. NOTE: Circuit breaker cover is removed for • “OFF” position turns off running illustration purposes. generator, prevents unit from starting A - Circuit Breaker — Protects the system from and resets any detected faults.
- Page 12 NOTE: Generator is shown with access door removed. D - Alternator Data Plate - Lists alternator data A - Over Temperature Switch - Switch for auto- specific to the Marathon alternator assembly. matically making or breaking an electrical circuit at predetermined temperature. Will signal the E - Battery - Stores and supplies electrical system control panel to shut down the generator energy.
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Page 13: Generator Clearances
GENERATOR CLEARANCES drifting you may need to construct a windbreak to protect the unit. • Install the generator as close as possible to the transfer switch and fuel supply to WARNING reduce the length of wiring, conduit, and piping. Running engine gives off carbon mon- oxide, and odorless, colorless, poi- son gas. -
Page 14: System Connections
SYSTEM CONNECTION Low Voltage (LV) connections to signal fault contacts, transfer switch communications, remote LED and auxiliary 12VDC power are made to a removable ten-pin connector plug. Compare this illustration with the location of these important connections: A - 10 Pole Connector Plug B - Fault Contacts —... - Page 15 GENERATOR AC CONNECTION Grounding the Generator Ground the home generator per applicable SYSTEM codes, standards and regulations. There are two generator Ground lug locations. The one inside A single-phase, three-wire AC connection the alternator junction box next to the circuit system is used on the home generator.
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Page 16: Fuel Supply
FUEL SUPPLY 10F (5.6C) above 77F (25C). These factors must be considered when determining total generator Depending on the generator model number, the load. home standby generator was manufactured and shipped to run on natural gas or liquid propane vapor. No matter which type of fuel the generator WARNING was manufactured to run on, it can be field converted to operate on either type of fuel. -
Page 17: Engine Maintenance
SETTING THE EXERCISE TIMER GENERATOR MAINTENANCE The home generator is equipped with an Generator maintenance consists of keeping the exercise timer that will start and exercise the unit clean. Operate the unit in an environment system once every seven days. During this where it will not be exposed to excessive dust, exercise period, the unit runs for approximately dirt, moisture or any corrosive vapors. - Page 18 Changing Engine Oil Engine Coolant System With the engine cold, check the coolant level in the coolant recovery bottle, seen inside the Control Panel door. Maintenance instructions for engine coolant are found in the engine operator’s manual. CAUTION Avoid prolonged or repeated skin contact with used motor oil.
- Page 19 Servicing the Battery WARNING If it is necessary to service the battery, proceed as follows: Storage batteries give off explosive 1. Set control board System switch to OFF. hydrogen gas during recharging. 2. Remove 15 Amp fuse from control panel. Slightest spark will ignite hydrogen 3.
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Page 21: Section 2 - Troubleshooting
SECTION 2 - TROUBLESHOOTING How to ACCESS the System Control Panel The system control panel is mounted behind the SYSTEM CONTROL PANEL(SCP) face of the control panel (Figure 1,A). 1. Remove the control panel door. The System Control Panel (SCP) is a printed circuit board that is integrated with the control panel of the Home Standby System. -
Page 22: Fault Code Indications
The 8-pin connector (A) is wired to the internal The functions of the 8-pin connector is shown in systems of the unit and is the primary point of (Figure 5). measurement for troubleshooting. The connector supplies 240VAC from UTILITY power. The 10- pin connector (B) is used for optional generator Vacant features. -
Page 23: Stopping The System For Maintenance
For example, “FC_1” (Fault Code) on the control STOPPING THE SYSTEM FOR panel display indicates Low Battery Voltage and MAINTENANCE the remote LED would repeatedly flash once with a pause until it’s reset or the condition is corrected. “FC_2” Low Oil Pressure would cause the remote LED to repeatedly flash twice and WARNING pause. -
Page 24: Generator Ac Connection System
GENERATOR AC CONNECTION SYSTEM A single-phase, three-wire AC connection is used in the Home Generator System. The stator assembly consists of a pair of stationary windings with two leads brought out of each winding. The junction of leads L2 & L3 forms the neutral lead, as shown schematically and as wiring diagram (Figure 6). -
Page 25: (Fault Code_1) Dead Unit/Low Battery Voltage
FC_1 DEAD UNIT/LOW BATTERY VOLTAGE Figure 7... - Page 26 (FC_1) NOTE: The trickle charge circuit is a float charger type. 240VAC UTILITY is delivered from DEAD UNIT/LOW BATTERY the fuses in the transfer switch to the fuses in the VOLTAGE generator circuit breaker panel. From there it flows to the 2 spade connectors mounted directly on the system control panel board.
- Page 27 trickle charge output, a fully charged battery must be installed in order to turn the trickle charge on. 1. Set SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system contol panel. 3. Inspect the fuse to see if blown. •...
- Page 28 Test 3 - Check 50 Amp Battery Fuse WARNING Utility voltage is present at the system contol panel board. Use caution to avoid personal electrical shock or damage to the system. 1. Inspect the 50 Amp fuse in Wire #13 located close to the starter motor (Figure 10,A).
- Page 29 4. Set meter to measure AC Voltage. Connect test leads across Wires #92 and #93. 240 VAC Utility should be measured (Figure 12). Figure 12 Figure 13 • If no voltage is measured, proceed to TEST 6. 5. Check the two fuses located inside the •...
- Page 30 • If 240 VAC Utility voltage is present at replace wiring between Utility power the fuse connections, but not at the and the fuse holder. sytem control panel, repair any wiring TEST 8 - Check ECU Fuse. between the fuses and the system 1.
- Page 31 6. Measure for 12 VDC at fuse on load side, Wire #15A (Figure 18). Figure 18 • If voltage is present at the fuse but not present at Pin #1, Wire #15A on the CMA, repair/replace wiring between the 50 Amp fuse and the ECU fuse. •...
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Page 33: (Fault Code_2) Low Oil Pressure
FC_2 LOW OIL PRESSURE Figure 19... - Page 34 (FC_2) 2. Reset the fault code detection system. LOW OIL PRESSURE SEE RESETTING THE FAULT CODE DETECTION SYSTEM ON PAGE 19 . 3. Start the generator and listen for any abnormal sounds that might indicate WARNING engine damage from low oil. Battery posts, terminals, and related SEE TESTING MANUAL OPERATION (NO LOAD) accessories contain lead and lead...
- Page 35 TEST 3 - Check Oil Pressure Switch 1. If it is not already, install the LOP switch. 2. Turn the SYSTEM switch to AUTO. Push and hold the MANUAL OVER-RIDE switch to start the engine. 3. With the engine running, check the switch with a continuity tester The switch contacts should be open (no continuity).
- Page 37 Figure 22...
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Page 38: (Fault Code_3) Low Output Voltage
(FC_3) TEST 1 - Measure Circuit Breaker Load-Side Voltage LOW OUTPUT VOLTAGE 1. Remove the cover from the generator circuit breaker. SEE TESTING MANUAL OPERATION (NO LOAD) The low voltage shutdown feature is designed to ON PAGE 52. protect the generator and its loads from an 2. - Page 39 2. Remove the 15 Amp system control panel fuse. 3. Gain access to the Automatic Voltage Regulator (AVR). Position control panel assembly and secure secure with tie straps as needed. (Figure 25). Figure 24 • If no voltage is present: A.
- Page 40 TEST 5 - Test Alternator Windings There are four components that contain windings that form an electrical path of low resistance. Each component can be checked for continuity. To Check Winding for Continuity: 1. Using meter, measure the loop resistance of the following four components: •...
- Page 41 Insulation Resistance Test 4. At the same time, touch the other test lead This test measures the quality of the insulation to the diode mounting nut (Figure 31). materials that keep the electrical windings and the generator’s steel core seperated. Dust, dirt, and moisture can cause the insulation to erode over time.
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Page 43: (Fault Code_4) Engine Fails To Start/Fails To Crank
Figure 33... - Page 44 (FC_4) This fail code directs the service technician to examine systems that could be preventing the ENGINE FAILS TO START unit from operating. For example: • No Alternator Output Voltage • Circuit Breaker in OFF position Whenever the unit is directed to start (MANUAL •...
- Page 45 ENGINE FAILED TO START TEST 2 - Check SCP Output TEST 1 - Check Fuel Solenoid Signal 1. Turn SYSTEM switch to OFF. WARNING 2. Remove the 15 fuse from the system control panel. Utility voltage is present at the system 3.
- Page 46 9. Turn the SYSTEM switch to OFF. TEST 3 - Check Ignition Coil Signal 1. Turn the SYSTEM switch to OFF. 10. Remove the 15 Amp fuse from the system control panel. 2. Remove the 15 Amp fuse from the system control panel.
- Page 47 TEST 4 - Check Fuel Supply Pressure To Test ECU Inputs: 1. Install Briggs & Stratton manometer 1. Turn the SYSTEM switch to OFF. #19495 as illustrated in (Figure 38) to 2. Remove the 15 Amp fuse from the system verify that fuel pressure is available to the control panel.
- Page 48 7. Reinstall the 15 Amp fuse in the system control panel. 8. Turn SYSTEM switch to AUTO. 9. While observing the meter, push and hold the MANUAL OVER-RIDE button. Battery voltage should be measured. Turn SYSTEM switch to OFF. • If battery voltage is measured, proceed to Step 10.
- Page 49 4. Unscrew RPM sensor one complete rotation. 5. While holding sensor in position, tighten lock nut. Figure 44 17. Approximately 285 - 295 Ohms should be measured. • If resistance is outside of this range, check for open/shorted wiring or RPM sensor.
- Page 50 Figure 46...
- Page 51 CRANKING FAILURES TEST 2 - Check Starter Contactor Signal 1. Set meter to measure DC Voltage. TEST 1 - Check Battery Components Connect positive (+) test lead to Wire #56 1. Check the condition and electrical at the starter contactor (Figure 48). integrity of all wires, connectors, and cables throughout the home standby unit.
- Page 52 Figure 50 • If battery voltage is measured at Wire Figure 49 #15A, Pin #1 but was not measured during the test at TEST 3, Step 4-7, 5. Reinstall the 15 Amp fuse in the system verify system control panel ground at control panel.
- Page 53 Figure 52 • A blown fuse indicates a short in the circuit. Because this fuse is designed to protect the ECU and its functions, a blown fuse would likely be related to something in the ECU or throttle control. For troubleshooting information, contact Power Solutions, Inc.
- Page 55 Figure 53...
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Page 56: (Fault Code_5) Under Frequency
(FC_5) TEST 1 - Check No-Load & Full-Load Frequency UNDER FREQUENCY For the following procedures, we recommend the The troubleshooting steps for under-and over- use of Briggs & Stratton Tach and Hour meter frequency faults are identical. Refer to Fig. 29 to (#19389) and Briggs &... - Page 57 Figure 55 3. With the unit running, measure the frequency at L1 and L2 at the system Figure 54 control panel pins (Fig 56). Check Full-Load Frequency 1. Turn off Utility power to the transfer switch. The generator should start and the transfer switch should transfer.
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Page 58: (Fault Code_6) Over Frequency
(FC_6) OVER FREQUENCY The troubleshooting steps for under and over frequency faults are identical. Refer to (Figure 30) to troubleshoot (FC_5) & (FC_6) fault indications. WARNING Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. - Page 59 Figure 57...
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Page 60: (Fault Code_7) High Temperature
(FC_7) TEST 1 - Check Over-Temperature Switch 1. Turn SYSTEM switch to OFF. HIGH TEMPERATURE 2. Remove the 15 Amp fuse from the system The contacts of the Over Temperature Switch control panel. (OTS) are normally open. If the engine coolant 3. - Page 61 Figure 59 5. Remove wire and measure for short-to- ground between Wire #95 and ground (Figure 60). Figure 60 • If a short-to-ground is measured, repair and/or replace the wiring as necessary. • If no short-to-ground is measured, replace the system control panel. 6.
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Page 62: (Fault Code_8) Transfer Switch Failure
(FC_8) TRANSFER SWITCH FAILURE A transfer switch with a compatible Air Conditioning Control Module (ACCM III or later version) is required for this feature to function. This module monitors the transfer switch during normal utility power and during standby power. Not all transfer switches will have this feature. -
Page 63: Section 3- Specifications & Reference
MODEL......... - Page 64 BLACK BATTERY BLACK GEN. CONTROL STARTER ENGINE N.O. MOTOR BATTERY FUSE N.C. TxRx ECU FUSE TRANSFER SWITCH COMMUNICATION 20 AMP 15 AMP TxRx GND. +LED O (+) REMOTE LED OUTPUT DELPHI 12182183 POWER FUSE +12VDC, 0.5A OUTPUT 15 AMP +12 VDC COIL DELPHI PURPLE...