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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 & Stratton Corporation.
It is also assumed that they have been trained in the
recommended
servicing procedures
for these products, which includes the use of mechanics hand tools and any
special tools that might be required.
Proper service and repair is important to the safe, economical
and reliable operation
of all engine driven
systems.
The troubleshooting,
testing, service and repair procedures
described in this guide are effective methods of
performing
such operations.
We could not possibly know of and advise the service trade of all conceivable procedures
or methods by which a
service might be performed,
nor of any possible hazards and/or results of each procedure
or method. We have
not undertaken
any such wide evaluation. Therefore,
anyone who uses a procedure
or method not described by
the manufacturer
must first satisfy himself that neither his safety, nor the safety of the product, will be
endangered by the service or operating procedure
selected.
All information, illustrations, and specifications
contained in this guide are based on the latest production
information
available at the time of publication.
However,
Briggs & Stratton Corporation
reserves the right to
change, alter, or otherwise
improve the product at any time without
prior notice.
Some components
or assemblies of the product
described in this guide may not be considered
repairable.
Disassembly, repair and reassembly of such components
may not be included in this guide.
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© 2004 Briggs & Stratton
Corporation
All rights
reserved.
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Summary of Contents for Briggs & Stratton 1938

  • Page 1 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...
  • Page 2 Service &Troubleshooting Guide - Home Generator Systems Model 1 938 (lOkW)Table ofContents MODEL 1938 (10KW) FUEL SUPPLY GENERAL INFORMATION CONTROL MODULE CONNECTORS TRANSFER SWITCH MODULE CONNECTORS SAFETY RULES In the Interest of Safety TROUBLESHOOTING Safety Practices TROUBLESHOOTING FAULTS ACCESS TO THE GENERATOR Dead Unit...
  • Page 3: Table Of Contents

    Service & Troubleshooting Guide - Home Generator Systems Model 1938 (lOkW) Table of Contents REMOVING MECCALTE GENERATOR GENERATOR ASSEMBLY Roof Removal Muffler Box Removal SPECIFICATIONS Remove Fuel Line From Regulator Generator Alternator Bulkhead Removal Engine Removing The Generator Blind End Cover Removal ENGINE MAINTENANCE Generator...
  • Page 4 Service & Troubleshooting Guide - Home Generator Systems _& S_ra_fa. Model 1938 (10kW) General Information GENERAL INFORMATION MODEL 1938 (I 0KW)
  • Page 5 _& St_a. Service & Troubleshooting Guide - Home Generator Systems '_°_:_ Model 1938 (10k_)General Information OTES • • " • ... _...... ]..]..i... i....i..i..i ..!..!.._ ..i......i..i ..i _....i......
  • Page 6: Safety Rules

    Service &Troubleshooting Guide Home Generator Systems St_an Model 1938 (10kW) G eneral Information SAFETYRULES In the Interest of Safety CAUTION: Indicates a hazard DANGER which, if not avoided might This manual outlines the construction, result in death or serious function and servicing procedures injury.
  • Page 7: Safety Practices

    _&St_on Service & Troubleshooting Guide ' Home Generator Systems Model 1938 (I OkW) General Information Safety Practices Home Standby generators • Do not attempt to modify the DANGER produce a high voltage that can unit or use it for any application cause an extremely dangerous it was not designed for.
  • Page 8 Service &Troubleshooting Guide - Home Generator Systems St_an _ Model 1938 (lOkW)General Information ACCESSTO THEGENERATOR The AIR INTAKE DOOR does not have locks or lift The Home Generator System is equipped with an enclosure that has four access doors (Figure I). The doors are named handles.
  • Page 9 _& Stra_on Service & Troubleshooting Guide ' Home Generator Systems Model 1938 (I OkVV) General Information GENERATOR COMPONENTS ° ° Air Cleaner m Uses a dry type filter element and foam Exhaust Port m High,performance muffler lowers engine precleaner to prevent dirt and dust from being drawn into noise to comply with most residential codes.
  • Page 10 Service &Troubleshooting Guide - Home Generator Systems St_an _ Model 1938 (lOkW)General Information SYSTEH CONTROLS I 5 Amp Fuse -- Protects the Home Generator System • OFF position turns off running generator, takes system DC control circuits. If the fuse has blown (melted open) or out of Automatic mode and resets any detected faults.
  • Page 11 Service & Troubleshooting Guide - Home Generator Systems StPa_n _ Model 1938 (IOkVV)General Information Generator Clearances The generator enclosure should be a minimum of 3 ft. (.9 meter) from combustible material. At least 3 ft. (.9 meter) of access room all around the enclosure should be available. The unit's exhaust port should be at least 5 ft.
  • Page 12 Service & Troubleshooting Guide - Home Generator Systems __& Sf_a, Model 1938 (I OkW) General Information Electrical Checks NOTE: If either parameter is outside these ranges, With the AUTO/OFF/MANUAL switch set to OFF: perform the Engine Adjustments described on page •...
  • Page 13: Utility Fail

    _& Stolon Service & Troubleshooting Guide - Home Generator Systems Model 1938 (I 0kW) General Information The actual system operation is not adjustable and is Generator AC Connection System sequenced by sensors and timers on the control board, as A single-phase, three-wire AC connection system is used in follows:...
  • Page 14: Stopping The System

    Service & Troubleshooting Guide - Home Generator Systems __& Sf_a, Model 1938 (I OkW) General Information Generator Load Tests Checking Automatic Operation To test the generator with electrical loads applied, proceed To check the system for proper automatic operation, as follows: proceed as follows: •...
  • Page 15: Reconfiguring The Fuel System

    _& Stra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (I 0kVV) General Information Reconfiguring The Fuel System Setting Exercise Timer The engine of your Home Generator System is factory The Home Generator System is equipped with an exercise calibrated to run on natural gas (NG).
  • Page 16: Power During Fault Conditions

    Service &Troubleshooting Guide - Home Generator Systems St_an _ Model 1938 (lOkW)General Information Power During Fault Conditions Whenever the Home Generator System is in an uncorrected fault condition, the automatic transfer switch resets to UTILITY POWER. This means that when utility power is restored, it will automatically be applied to all the...
  • Page 17: Led Fault Light Conditions

    _& Stra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (I OkVV) General Information LED Fault Light Conditions Resetting The Fault Detection System The generator may have to run for long periods of time with no operator present. For that reason, the CMA is An operator or technician must reset the fault detection equipped with sensing circuits that automatically...
  • Page 18: Module Connectors

    Service & Troubleshooting Guide - Home Generator Systems __& Sf_an Model 1938 (I 0kW) General Information Control Module Assembly (CMA) Connector Pins, Functions & Wire Numbers seen from wire side of connector in the generator) P-I_ Crank Disconnect @ 20VAC •...
  • Page 19 _& St_a. Service & Troubleshooting Guide - Home Generator Systems '_°_:_ Model 1938 (10k_)General Information OTES • • • • ... _...... i..i..i... i.... i..i..i..!..!..i..i......i..i ..i _....i...... i..
  • Page 20 Service & Troubleshooting Guide - Home Generator Systems __sggs& S_ra_fa. Model 1938 ( I 0kW) Troubleshooting TROUBLESHOOTING INFORMATION MODEL 1938 (I 0KW)
  • Page 21: Led Faults

    _& Stra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (lOkW) Troubleshooting TROUBLESHOOTING LED FAULTS Follow the recomendations of your meter's instruction manual. • Install DC Amp meter between Negative (-) battery Dead Unit / Low Battery Voltage: terminal and Negative (-) battery cable.
  • Page 22: Check The Step-Down Transformer

    Service & Troubleshooting Guide - Home Generator Systems __& Sf_a, Model 1938 (I OkW) Troubleshooting o• If 20-26VAC is present (going in) on Pins #14 & Pin #15, but 12VDC was not measured (coming out) at Pin #12, Wire #15, with the AUTO/OFF/MANUAL switch set to OFF: Verify Ground...
  • Page 23 _& Stra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (lOkW) Troubleshooting •. If 240VAC is not present at wires NI & N2 in generator: Low Oil Pressure: (Two Blinks [ • • ]) • Measure for 240VAC at UTILITY CONNECTION lugs The generator...
  • Page 24: Access To The Generator

    Service & Troubleshooting Guide - Home Generator Systems __& Sf_an Model 1938 (I OkW) Troubleshooting • Replace the 15 Amp fuse. • Close the generator circuit breaker. • Set AUTO/OFF/MANUAL switch to AUTO. • Remove utility power and verify system operation. •...
  • Page 25: Troubleshooting Procedure

    _& Stolon Service & Troubleshooting Guide - Home Generator Systems Model 1938 (10kW) Troubleshooting Engine Fails Start: (Four Blinks [ ..This is a feature of the control module assembly (CMA) that prevents the standby unit from damaging itself by continually attempting to start, in spite of a problem that...
  • Page 26: Engine Cranks But Fails To Start

    Service & Troubleshooting Guide - Home Generator Systems __& Sf_a. Model 1938 (I OkW) Troubleshooting Engine Cranks But Fails To Start: Ensure that adequate fuel is available to operate the standby WARNING system. • Inspect the fuel supply tank to verify that the main supply valve is open.
  • Page 27: Gas Regulator

    ra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (lOkW) Troubleshooting o• If the proper fuel pressure is not present: • Repair and/or replace fuel delivery system. • Re-test fuel pressure as described above. •• If fuel pressure is acceptable: Check the Fuel Solenoid.
  • Page 28 Service & Troubleshooting Guide - Home Generator Systems __& Sf_a. Model 1938 (I 0kW) Troubleshooting Atmospheric pressure then forces the diaphragm toward the o• If no fuel pressure is measured: vacuum, depressing the lever and pulling the valve seat away •...
  • Page 29: Check Ignition Spark

    _& Stra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (10kW) Troubleshooting Check Ignition Spark: NOTE: Remember that the CMA only delivers 12VDC to the starter contactor for 15 seconds and • Turn off the manual fuel valve that is located on the then rests for 15 seconds.
  • Page 30: Low Frequency: (Five Blinks

    Service & Troubleshooting Guide - Home Generator Systems __& Sf_an Model 1938 (I 0kW) Troubleshooting Low Frequency Troubleshooting Procedure: Check engine RPM. • Set engine RPM to 3600. as specified in the BRIGGS & STRATTON engine service manual. Verify that the Control Module Assembly (CMA) is grounded.
  • Page 31 _& Stra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (lOkW) Troubleshooting NOTE: Follow the Frequency Measurement instructions that apply to the type of meter you are using. o• If frequency and voltage are correct: Verify Ground connection on C MA circuit board.
  • Page 32 Service & Troubleshooting Guide - Home Generator Systems __& Sf_a, Model 1938 (I 0kW) Troubleshooting o• If 18VAC is measured while the engine is running: The reason for this latitude in sensing output frequency is that often a governor will hunt for the desired setting. This •...
  • Page 33 _& Stra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (lOkW) Troubleshooting o• If continuity is measured: High Oil Temperature: (Seven Blinks [ ..• Select MANUAl. at the AUTO/OFF/MANUAL switch The contacts of the temperature switch are normally open (NO).
  • Page 34 Service & Troubleshooting Guide - Home Generator Systems __sggs& S_ra_fa, Model 1938 ( I OkW) Troubleshooting • Check that all ducting, gaskets, shrouding and enclosure OTES panels are in place. NOTE: With more than two access doors removed, the engine will run hotter than designed.
  • Page 35 _& St_a. Service & Troubleshooting Guide - Home Generator Systems '_°_:_ Model 1938 Troubleshooting (I 0kW) OTES i i _ i i i i .._ .._ ......i..]..i ..i ... i....i..i..!..
  • Page 36: Generator Assembly

    Service & Troubleshooting Guide - Home Generator Systems _ stolon Model 1938 (10kW) Generator Assembly GENERATOR ASSEMBLY MODEL 1938 (I 0KW)
  • Page 37: Specifications

    ra_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (10kW)Generator Assembly SPECIFICATIONS: Model 1938 Generator Rated Maximum Power (LI>*)................10 kW Rated Maximum Load Current: at 240 Volts ........................ 41.6 Amps at 120 Volts ........................ 83.4 Amps Rated AC Voltage ......................120/240 Volts Rated Frequency.
  • Page 38: Engine Maintenance

    Service &Troubleshooting Guide ' Home Generator Systems Model 1938 (I OkW) Generator Assembly • After the oil is drained, grasp the oil drain fitting and Engine Maintenance rotate it clockwise until it locks in place. Position the oil drain hose in its storage clip. •...
  • Page 39: Service The Air Cleaner

    &St_on Service & Troubleshooting Guide - Home Generator Systems Model 1938 (10kW) Generat0r Assembly Service Air Cleaner Inspect the spark arrester as follows: The engine's air cleaner is one of the most important areas • Using a powerful flashlight, examine the circular screen to maintain.
  • Page 40: Engine Adjustment

    Service & Troubleshooting Guide ' Home Generator Systems Model 1938 (I OkW) Generator Assembly Engine Adjustment It is commonly known that there are regional variances in the combustibility of natural gas. Each standby unit is adjusted at the factory for correct NG operation.
  • Page 41: I Okw Resistance Values

    Service &Troubleshooting Guide, H ome Generator Systems _& StmH_ _ Model 1938 ( 10kW) Generator Assembly I 0kW Rotor & Stator Resistance Values i oo0e. , unit ,PartNo i O.ms, 1938-0 10kW [192971GS 4.67/4.67] [Part No,[ Power 1192969GS1.109/.109 0.027 System Interconnections The Home Stand-by System circuit interconnections consist of "Utility Supply"...
  • Page 42: 10Kw Circuit Test Introduction

    Service & Troubleshooting GuideHome Generator Systems Model 1938 (10kW) G enerator Assembly I OkW Circuit Test Introduction This section is organized for the 10kW generator by "ease The troubleshooting section of this service manual contains of access" to the various components with the easiest page references to inspection procedures of specific...
  • Page 43: Checking The Stator Power Winding

    _& S_a_on Service & Troubleshooting Guide -Home Generator Systems Model 1938 (lOkW) Generator Assembly Checking The Stator Power Winding Checking The Battery Charge Through The Harness Winding (BCW) Through The Harness Access Requirements: • Access to CMA Board (Page 15) Access Requirements: •...
  • Page 44: Checking The Excitation Circuit

    Service & Troubleshooting Guide ' Home Generator Systems __'ggs _ s_o_o. Excitation Circuit •. If resistance reading is OK: Checking • Re-install/replace the capacitors Access Requirements: • Re-assemble the standby generator enclosure. • Roof Removal Page 46 • Muffler Box Removal Page 46 Checking The Stator...
  • Page 45: Winding (Bcw)

    &S_a_on Service & Troubleshooting Guide' Home Generator Systems Model 1938 (I 0kW) Generator Assembly See "Removing The Meccalte-Generator" (Page 46). •, If resistance reading is OK: • Check for defective lead wire between terminal block and circuit breaker. • Re-assemble the standby generator enclosure.
  • Page 46 Service &Troubleshooting Guide ' Home Generator Systems Model 1938 (10kVV) Generator Assembly NOTE: The rotor cannot be thoroughly inspected OTES without removing it from the generator assembly. In addition, detailed components of the rotor must be de-soldered in order to determine its servicability.
  • Page 47: Removing The Meccalte Generator

    & S_a_on Service & Troubleshooting Guide ' Home Generator Systems Model 1938 (I 0kW) Generator Assembly Removing The Meccalte-Generator Roof Removal CAUTION: Before enclosure disassembly: ' Turn Switch "OFF!! • Turn Fuel ,OFF, ,Remove 5 Amp Fuse The roof is secured to the "Standby" enclosure with four nuts that thread on studs welded to the structure of the roof, as shown in figure 45.
  • Page 48: Remove Fuel Line From Regulator

    Service & Troubleshooting Guide 'Home Generator Systems _4_'ggs _ s_o_o. Model 1938 (I 0kW) Generator _:_'_'_'_'_ Fuel Line From Regulator Removal The fuel line passes through a hole in the bulkhead and connects to a fitting on top of the regulator, as shown in figure 48A &...
  • Page 49: Alternator Bulkhead Removal

    _& S_a_on Service & Troubleshooting Guide ' Home Generator Systems _'_'_ Model 1938 (lOkW) Generat0r Assembly When these brackets have been removed: This procedure allows you access (Figure 52) to the following tests of the generator: • Disconnect cables from the battery, being careful to remove the negative (-) cable first.
  • Page 50 Service & Troubleshooting Guide ' Home Generator Systems _4_'ggs _ s_o_o. Model 1938 (I 0kW) Generator Assembly _:_'_'_'_ • Remove Wire #14, which is ganged to the fuel shut-off At this point, the alternator bulkhead is held to the solenoid. See Figure 56. mounting base with seven I/4"...
  • Page 51: Removing The Generator

    &S_a_on Service & Troubleshooting Guide ' Home Generator Systems Model 1938 (I OkW) Generator Assembly Removing The Generator With the alternator bulkhead removed as shown in figure 60, you are ready to begin removal of the Meccalte- Generator. NOTE: Do attempt to loosen or remove the hardware that attaches the isolation mounts to the enclosure base.
  • Page 52: Removing Rotor Through-Bolt (Stay Shaft Bolt)

    Service & Troubleshooting GuideHome Generator Systems Model 1938 (10kW) Generator Assembly Remove thenuts fromtheboltsthatmount t hestator housing to theengine a dapter (Figure 64). • Support the drive end of the generator with a suitable wooden block. • Remove the grounding lug from the stator housing Removing Rotor...
  • Page 53: Removing The Rotor Assembly

    _& Stolon Service & Troubleshooting Guide - Home Generator Systems Model 1938 (I OkW) Generator Assembly Removing The Rotor Assembly The rotor assembly is held to the tapered shaft of the • Extend the puller spindle until the housing clears the engine by means of the rotor through-bolt ("Stay Shaft...
  • Page 54: Inspecting The Rotor Assembly

    Service & Troubleshooting Guide Home Generator Systems __'ggs& Stm_o,' Model 1938 (I 0kW) Generator Assembly Inspecting The Rotor Assembly OTES It is not possible to check the serviceable condition of a rotor assembly without de-soldering specific corn ponents. The reading that is obtained by the process shown in figure 71 only gives the resistance value of the rotor winding.
  • Page 55 & St_a. Service & Troubleshooting Guide - Home Generator Systems ,,_,_,_o_,:_s Model 1938 (10kVV) Generator Assembly OTES "i ..'..i..!..:..!..!..!..!..i..!..;..:.."..i..:..:..i..:..i..:..i..... _..•...
  • Page 56: Appendix

    Service &Troubleshooting Guide - Home Generator Systems _ Stolon_ Model 1 938 (10kW) A ppendix APPENDIX...
  • Page 57: Cma Schematic

    Service & Troubleshooting Guide-Home Generator Systems Model 1938 ( 10kW) Appendix ... TT.RY t_SM-- LED LAMP PRESSURE O_85_0-_ RESISTOR MANUAL MODE (+ 12VOC WHEN ACTIVE)I 17---_O 0 5 oH_R25w sw__ AUTOMODE(+I2VDCWHENACTIVE) II90_239_ "'-'"_ CRANKDISCONNECTIJl0 O-_66 AUTO 7"r7 RSZ:ZJZ SETEXERC,SE(GNDWHENACT,VE)II,, 4--,,0----Oo...--_.O _€+.1_...
  • Page 58: Generator Wiring Diagram

    Service & Troubleshooting Guide - Home Generator Systems _ Stolon Model 1938 (10kW) Appendix ____...
  • Page 59: Amp Wiring Diagram

    & S_ton Service & Troubleshooting Guide - Home Generator Systems _"_:_ Model 1938 (10kVV) Appendix Neut © Main Distribution Panel Model 1917 Transfer Switch...
  • Page 60 Service &Troubleshooting Guide - Home Generator Systems _ Stolon Model 1 938 (10kW) A ppendix Connections: Torque Values In Main Distribution Panel: Minimum Maximum Refer To Panel Manufacturers' Specs. In Transfer Switch: 35 in-lb 45 in-lb Utility Connection Lugs 35 in-lb 45 in-lb Generator Connection Lugs 35 in-lb...
  • Page 61: Amp Wiring Diagram

    & Stolon Service & Troubleshooting Guide - Home Generator Systems Model 1938 (10kW) Appendix Main Distribution Panel Model 1814 Transfer Switch...
  • Page 62 Service & Troubleshooting Guide ' Home Generator Systems _4_'_'ggs _ S_o_o. Model 1938 (10kW) Appendix _:_'_'_'_'_ Connections: Torque Values In Main Distribution Panel: Minimum Maximum Refer To Panel Manufacturers' Specs. In Transfer Switch: Ground Lugs 45 in-lb 50 in-lb _r_c_ X n_ b_FCC Barrier Terminal Strip Screws 5 in-lb...
  • Page 63 & Stolon Service & Troubleshooting Guide - Home Generator Systems Model 1938 (10kW) Appendix @1111@ Main Distribution Panel Model 1929 Transfer Switch...
  • Page 64 Service & Troubleshooting Guide - Home Generator Systems __'_gJ _ s_o_o. Model 1938 (10kW) Appendix _:_'_'_'_ Connections: Torque Values In Main Distribution Panel: Minimum Maximum Refer To Panel Manufacturers' Specs. Generator Connection Lugs 35 in-lb 45 in-lb Ground Lugs 45 in-lb 50 in-lb In Generator Housing:...
  • Page 65: Transfer Switch Schematic

    TRANSFER SWITCH "f MAIN DISTRIBUTION GENERATOR SUPPLY Udlity Supply PAN EL 240VAC 240VAC O T2 O E2 __---b o, %', R" To Gen. 0_'-_ Utility Sensing _ 600VAC 2 AMP Fuse ¢0 CONTROL BOARD ¢0 N.C. CONTACTS SUPERVISORY CONTROL "O €0...
  • Page 66: Oil Heater

    Service & Troubleshooting Guide - Home Generator Systems Model 1938 (10kW) Appendix OIL HEATER Heater I. Remove the control panel and oil service doors as described on page 7. 2. Set the AUTO/OFF/MANUAL switch to the OFF position. 3. Set the generator's main circuit breaker to the OFF position.
  • Page 67 Service & Troubleshooting Guide - Home Generator Systems Model 1938 (lOkW) Appendix OTES iili iiiii!i !iifF----- ii2 i::!i ii i! I IIII iiiiiiiiiiii i ii iiii i iiiiiiiiii i ..._ ..: ..:..:...: ..: ..
  • Page 68: Volt Battery Warmer

    Service & Troubleshooting Guide - Home Generator Systems Model 1938 (10kW) Appendix _iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_ATT_:_YiiWA_:_ 240 Volt Battery Warmer I. Remove control panel and oil service doors as described on page 7. 2. Set AUTO/C)FF/MANUAL switch on generator's control panel to OFF. 3.
  • Page 69 Service & Troubleshooting Guide - Home Generator Systems Model 1938 (lOkW)Appendix OTES ...- ..; ..) ..:..-...- ..: ..! ..: ..:..- .;..: ..! ..: ..:..f.... • ..: ..:..:..:...: ..:..,..., ..:..:..: .., ..:.."...

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