Briggs & Stratton 040213 Service And Troubleshooting Manual
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Briggs & Stratton 040213 Service And Troubleshooting Manual

15000 watt home generator system
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15000 WATT HOME GENERATOR SYSTEM
SERVICE & TROUBLESHOOTING MANUAL
MODELS 040213 & 040234
Part# 276351GS - June 2006
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Summary of Contents for Briggs & Stratton 040213

  • Page 1 15000 WATT HOME GENERATOR SYSTEM SERVICE & TROUBLESHOOTING MANUAL MODELS 040213 & 040234 Part# 276351GS - June 2006 Page 1...
  • Page 2 FORWARD This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufactured by Briggs &...
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  • Page 5: Table Of Contents

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Table Of Contents 15000 WATT HOME GENERATOR SYSTEM SECTION 1 - GENERAL INFORMATION ................11 ACCESS TO THE GENERATOR .......................11 To remove an access door: ........................... 11 To install an access door: ..........................

  • Page 6: Test 2

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Table Of Contents SECTION 2 - TROUBLESHOOTING INFORMATION ............23 (FC_1) DEAD UNIT/LOW BATTERY VOLTAGE: ..................23 Test 1 Check Battery: ..............................23 Test 2 Check DC Amperage at Battery: ........................23 Test 3 Check AC Voltage Input: ..........................
  • Page 7 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Table Of Contents Test 6 Check Ignition Spark: ............................. 38 Test 7 Check Battery Components ........................... 38 Test 8 Check Starter Contactor Signal ........................39 Test 9 Check CMA Board Output ..........................
  • Page 8 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Table Of Contents SECTION 3 - UNIT DISASSEMBLY ..................53 REMOVING THE ACCESS DOORS ....................53 REMOVE THE ROOF ASSEMBLY ....................53 REMOVE THE EXHAUST BULKHEAD .....................53 REMOVE THE CONTROL PANEL BULKHEAD ................54...
  • Page 9 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Table Of Contents SECTION 4 - FINAL ADJUSTMENTS AND SPECIFICATIONS ..........61 OERATIONAL TESTS ........................61 Manual Operation Test (No Load) ......................... 61 Automatic Operation Test (Load Transfer) ....................62 Generator Load Test (Full Rated Electrical Capacity And Fuel Consumption) ..........
  • Page 10 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Table Of Contents Page 10...

  • Page 11: Section 1 - General Information

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 1 - General Information SECTION 1 - GENERAL INFORMATION ACCESS TO THE GENERATOR To remove an access door: • Insert a key into the lock of the access door you...

  • Page 12: Generator Components

    Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW) Section 1 - General Information GENERATOR COMPONENTS Exhaust Port 15 Amp Fuse - High performance muffler lowers engine noise - Protects the DC control circuits. to comply with most residential codes. Air Cleaner - Protects engine by filtering dust and debris out of Oil Dipstick...

  • Page 13: System Controls

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 1 - General Information SYSTEM CONTROLS Service Tool 15 Amp Fuse - For use by qualified service technicians - Protects the Home Standby Generator only.

  • Page 14: Generator Clearances

    Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW) Section 1 - General Information GENERATOR CLEARANCES Checking Oil Level Before placing the standby generator in service and at the recommended maintenance interval, check the The generator enclosure should be a minimum of 5 ft. engine oil level, as follows: (1.52 meter) from any combustible material.

  • Page 15: Replacing The Spark Plugs

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 1 - General Information 6. Coat the o-ring of the new filter with fresh clean 3. Service cartridge by tapping gently on a flat engine oil. Turn the new filter clockwise by hand surface.

  • Page 16: Reconfigure The Fuel System

    Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW) Section 1 - General Information NOTE 12. Reinstall the 15 Amp fuse. : Air density is less at high altitudes, resulting in less available engine power. 13. Set the generator main circuit breaker Specifically, engine power will decrease 3.5% for 14.

  • Page 17: System Connections

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 1 - General Information SYSTEM CONNECTIONS 10 Pin Connector Fault Contacts Transfer Switch Communications Remote LED Output +12VDC,.5Amp Output 240VAC Utility 2 Pin Connector Wiring For The 2-Pin Connector:...

  • Page 18: Setting The Exercise Timer

    Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW) Section 1 - General Information SETTING THE EXERCISE TIMER CONTROL MODULE ASSEMBLY (CMA) The Home Standby Generator System is equipped with The Control Module Assembly (CMA) is a printed circuit an exercise timer that will start and exercise the system board that is integrated with the control panel of the once every seven days.

  • Page 19: Access To The Cma Board

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 1 - General Information Access To The CMA Board receptacles have matching halves. The 2-pin plug supplies 240VAC from UTILITY power. The 10-pin plug The CMA is mounted behind the control panel door is used for optional generator features.

  • Page 20: Fault Code Indications

    Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW) Section 1 - General Information A detailed illustration of the entire connector, as well as For example, on the digital display would indicate “FC_1” the functions of each individual pin, is given in (Fig. 11). a low battery voltage condition and the remote LED would flash once, pause, flash once again and continue Vacant...
  • Page 21 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 1 - General Information Page 21...
  • Page 22 Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW) Section 1 - General Information (FC_1) DEAD UNIT/LOW BATTERY VOLTAGE Test 2 Measure DC Test 1 Amperage on Check Battery Wire #13 at battery. Charge/Replace Battery Test 3 Check AC voltage (+) Amp input at CMA 2-Pin...

  • Page 23: Section 2 - Troubleshooting Information

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information SECTION 2 - TROUBLESHOOTING INFORMATION (FC_1) Test 1 Check Battery: DEAD UNIT/LOW BATTERY VOLTAGE: 1. Switch the SYSTEM switch to 2. Remove 15 Amp fuse.

  • Page 24: Test 3

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Test 3 Test 4 Check AC Voltage Input: Measure DC Output Voltage at the CMA 1. Disconnect the (-) negative battery cable.
  • Page 25 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Page 25...

  • Page 26: (Fc_2)

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_2) Test 1 Low Oil Pressure Test Measure for short-to-ground on Wire #85. Repair/replace Shorted? Wire #85 Reset FC Fault Reset FC...

  • Page 27: Low Oil Pressure

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_2) Test 1 Measure for Short-To-Ground LOW OIL PRESSURE: 1. Select at the SYSTEM switch. 2. Remove the 15 Amp fuse.

  • Page 28: Test 2

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Test 2 Test 3 Check Engine Oil Pressure Check Oil Pressure Switch 1. Remove oil pressure switch and install oil 1. With the switch installed, pressure gauge.
  • Page 29 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Page 29...

  • Page 30: (Fc_3)

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_3) Low Output Voltage Test 1 Measure circuit breaker load-side voltage. Test 2 240VAC? Measure voltage at E1 & E2 at CMA...

  • Page 31: Low Output Voltage

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_3) 4. Measure the voltage at the output side of the circuit breaker (Fig. 18). LOW OUTPUT VOLTAGE: About 240VAC should be measured.

  • Page 32: Measure Circuit Breaker Line Voltage

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information • Retest voltage. If voltage is present: • Ensure that the circuit breaker is in the open position. • Replace CMA board.
  • Page 33 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Page 33...
  • Page 34 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_4) Engine Cranks But Fails To Start Test 1 Test 2 Test 3 OK? Yes OK? Yes Check Fuel Visually inspect...

  • Page 35: (Fc_4)

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_4) Troubleshooting Engine Start Failures: ENGINE FAILS TO START: 1. Reset the fault code detection system (See “Resetting The Fault Code Detection System” on page 20).

  • Page 36: Test 3

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information 5. Visually inspect the condition of the wiring, connectors and terminals associated with the following components: • Oil Pressure and Oil Temperature 11 to 14 inches of water (in.
  • Page 37 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information On Site If fuel is detected at exhaust pipe during the starting sequence: • See “Test 6 Check Ignition Spark:” on page...

  • Page 38: Test 5

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Test 5 Test 6 Check Fuel Regulator Check Ignition Spark: • Refer to Fig. 25 for the following procedure. • Turn off the manual fuel valve to the standby generator.

  • Page 39: Test 8

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Some areas of particular focus are shown in (Fig. 27). 4. Check the unit grounding cable (Fig. 29). Fig. 29 - Check Grounding Cable...

  • Page 40: Test 9

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information If no voltage is present at the coil terminals of the starter contactor: Test 9 Check CMA Board Output Gain access to the CMA circuit board (See “Access To...
  • Page 41 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Page 41...
  • Page 42 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_5) Under Frequency & (FC_6) Over Frequency Test 1 Measure no-load and full-load output frequency at circuit breaker. Test 2 Within...

  • Page 43: (Fc_5)

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_5) 3. Set SYSTEM switch to AUTO push and hold to start unit. MANUAL_OVERIDE UNDER FREQUENCY: CAUTION: Follow the measurement instructions that apply to the type of frequency meter you are using.

  • Page 44: Test 2

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information If frequency at no load is correct: Test 2 Measure Frequency at E1 & E2 Check Full Load Frequency Gain access to the generator control panel (See “Access...

  • Page 45: (Fc_6)

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_6) OVER FREQUENCY: IMPORTANT : The troubleshooting steps for under and over frequency faults are identical. Refer to (Fig. 33) to troubleshoot &...
  • Page 46 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_7) High Oil Temperature Test 1 Check OTS Replace OTS Shorted? Reset Fault Detection Start Unit Test 2 Check Wire #95...

  • Page 47: (Fc_7)

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_7) HIGH OIL TEMPERATURE: This feature protects the generator unit from running at excessively high temperatures. The contacts of the Over Temperature Switch (OTS) are normally open (NO).

  • Page 48: (Fc_8)

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information (FC_8) TRANSFER SWITCH FAILURE: This is an optional feature of the Home Generator System that is designed to display fault conditions that relate to the transfer switch.

  • Page 49: 15Kw Winding Test Index

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information 15KW WINDING TEST INDEX The troubleshooting section of this service manual contains page references to inspection procedures for specific generator components. These components are related to the various LED fault code detection indications.

  • Page 50: Checking The Stator Winding Through The Harness

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information CHECKING THE STATOR WINDING CHECKING THE EXCITATION WINDING THROUGH THE HARNESS IN THE GENERATOR Access Requirements: Access Requirements: • Access to CMA Board (Page •...

  • Page 51: Checking The Stator Power Winding

    Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information CHECKING THE STATOR POWER CHECKING THE ROTOR WINDING WINDING Access Requirements: • Unit Disassembly (Page Access Requirements: • Roof Removal (Page Related Fault Indications: •...
  • Page 52 Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW) Section 2 - Troubleshooting Information Page 52...

  • Page 53: Section 3 - Unit Disassembly

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15Kw) Section 3 - Unit Disassembly Information SECTION 3 - UNIT DISASSEMBLY NOTE REMOVE THE EXHAUST BULKHEAD : Prior to unit disassembly, the unit must be turned...

  • Page 54: Remove The Control Panel Bulkhead

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 3 - Unit Disassembly Information REMOVE THE CONTROL PANEL 2. Remove the 8-pin connector from the control panel (CMA). BULKHEAD 3. Disconnect the 2 and 10-pin connectors.

  • Page 55: Disconnect Fuel Solenoid

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 3 - Unit Disassembly Information Disconnect Fuel Solenoid 4. Remove the two bolts ( Fig. 57) that secure the mounting bracket for the solenoid/regulator 1. Remove (Fig.

  • Page 56: Remove The Muffler Assembly

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 3 - Unit Disassembly Information 6. Remove the fasteners and lift the bulkhead from 3. Slide the muffler over the engine oil dipstick and the base of the standby generator (Fig. 59).
  • Page 57 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 3 - Unit Disassembly Information 2. Take careful note of the wiring connections and 5. Using a 11/2” socket, with a 1/2” breaker bar, disconnect the wires that come from the external rotate the engine crankshaft with the flywheel harness (Fig.
  • Page 58 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 3 - Unit Disassembly Information CAUTION : Do not lift the entire engine/alternator/base CAUTION : Do not damage the internal with this hook. Damage to the unit may occur.

  • Page 59: Removing The Rotor Assembly

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 3 - Unit Disassembly Information REMOVING THE ROTOR ASSEMBLY INSPECTING THE ROTOR ASSEMBLY The rotor assembly is held to the tapered shaft of the It is not possible to check the serviceable condition of a engine by means of the rotor through-bolt (“Stay Shaft...

  • Page 60: Removing The Engine Adaptor

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 3 - Unit Disassembly Information REMOVING THE ENGINE ADAPTOR 1. Remove the four bolts (Fig. 74) that secure the engine adaptor to the engine. Fig. 74 - Engine Adaptor Mount Bolts 2.

  • Page 61: Section 4 - Final Adjustments And Specifications

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications SECTION 4 - FINAL ADJUSTMENTS AND SPECIFICATIONS OERATIONAL TESTS If the unit failed to start: • Reset fault code detection system. (See “Resetting The Fault Code Detection System”...

  • Page 62: Automatic Operation Test (Load Transfer)

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications NOTE : If the unit has run for 5 minutes or more, it will transfer the load back within 10 seconds. If...
  • Page 63 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications 8. Connect an accurate AC frequency meter to the GENERATOR CONNECTION (B&S #19543) CAUTION : If no load frequency falls out of stated lugs in the transfer switch.

  • Page 64: Specifications

    MODEL.........

  • Page 65: Wiring Diagram - Model 071013 - Load Control Center

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications WIRING DIAGRAM - MODEL 071013 - LOAD CONTROL CENTER Page 65...

  • Page 66: Schematic - Models 040213 & 040234 - Generator

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications SCHEMATIC - MODELS 040213 & 040234 - GENERATOR Page 66...

  • Page 67: Wiring Diagram - Models 040213 & 040234 - Generator

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications WIRING DIAGRAM - MODELS 040213 & 040234 - GENERATOR Page 67...

  • Page 68: Schematic - Models 1813 & 1814 - Transfer Switch

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications SCHEMATIC - MODELS 1813 & 1814 - TRANSFER SWITCH Page 68...

  • Page 69: Wiring Diagram - Models 1813 & 1814 - Transfer Switch

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications WIRING DIAGRAM - MODELS 1813 & 1814 - TRANSFER SWITCH Page 69...

  • Page 70: Schematic - Models 071008 & 071009 - Transfer Switch

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications SCHEMATIC - MODELS 071008 & 071009 - TRANSFER SWITCH Page 70...

  • Page 71: Wiring Diagram - Models 071008 & 071009 - Transfer Switch

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications WIRING DIAGRAM - MODELS 071008 & 071009 - TRANSFER SWITCH Page 71...

  • Page 72: Schematic - Models 071010 & 071011 - Transfer Switch

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications SCHEMATIC - MODELS 071010 & 071011 - TRANSFER SWITCH Page 72...

  • Page 73: Wiring Diagram - Models 071010 & 071011 - Transfer Switch

    Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications WIRING DIAGRAM - MODELS 071010 & 071011 - TRANSFER SWITCH Page 73...
  • Page 74 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications Page 74...
  • Page 75 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications Page 75...
  • Page 76 Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW) Section 4 - Final Adjustments and Specifications Page 76...

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