Briggs & Stratton 1897, 1976, 1977 7kW Service Manual
Contents
1. 18 Generator AC Connection __________________________________________________________ 18 Control Module Assembly CMA Schematic 1 19 Six Pin Connector Voltage Regulator amp ee e e hh LLL eee 19 aa dt ya 20 Disconnect Switch amp Junction ____________________________________________________________________ 2l TROUBLESHOOTING LED FAULTS a 22 Low Oil Pressure Two Blinks ccce lccn 22 Troubleshoeting Procedure U UU U UU uuu Uu ee eae 22 Engine Fails To Start Four 1 23 Lu uei gt gt ee eee eee 23 Engine Cranks But Fails le Spek ee 23 Cs RE d rir 25 Check Ignition Spark 26 Service amp Troubleshooting Guide Home Standby Generator System Briggs Stration AEE Model 1897 1976 amp 1977 7000kW Table Of Contents Controls by Eaton s Culler Hammer TABLE OF CONTENTS Low Frequency Five 26 Troubleshooting ________________________________________________________________ 26 Over Frequency Six lt 5 9 __________________________________________________ 27 Troubleshoo ng OC CC e o u u uu y 27 Troubleshooting An Engine That Fai2. W wiwa kuk h w Um K Uw BUR S R W IN R W see W c cii RUS NE K OW k w k ae p Ok Uw R dr k k W che W k USER Jane de w X 3 S R TET II LT DI ns cL rr tes avin EAE TM Warn dh er OAK QU s Q s w er e W DU AA T Run WW CK eR Rc QUAKE CAI cas fn D S Re eL CO tin Re SET W W QN QU NU w WAQ mU Qc Ro m MIR Q 37 38
3. meee et tren tyre 319775 OI IOEI Dorsa TOKE MNT D I 3 57 90 6mm x 3 06 77 8mm Splice nepus MID 30 51 cu in 500cc PaK PIUS BRIGGS amp STRATTON 491055 m 030 0 76mm ey T Use only 5W 30 API Service Grade SJ or greater synthetic oil Oil Capacity w filter 1 5 qt 48 oz SE HN BRIGGS amp STRATTON 492932 PU Pili BRIGGS amp STRATTON 790217 90990909900909099090099090000909000099900909099900909099000090909000090000099090009099090009090900009090009009000009999099 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Briggs amp Stratton POWER PRODUCTS Controls by Eoton s Cuilar Hammer GENERATOR ENCLOSURE Figure Access To The Generator To Remove Roof Remove the four screws and lift off Figure 1 To Remove Access Door Remove roof as described above 2 Remove screw at top of access door 3 Pull access door outward away from unit while pulling door upward and out of base Door will come free of generator enclosure To Remove Front Panel Remove lower retaining screw 2 Lift front panel up and out of retaining clips on right and left side panels To Remove Left Side Panel Remov
4. For this reason rotor replacement should only be considered when all other possible faults have been eliminated CAUTION In order to prevent damaging the brushes assemble the stator to the engine adaptor first Then install the brush holder assembly 36 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Briggs amp Stratton POWER PRODUCTS Controls by Ecton s Cutler Hammer ER N a aa ca RT dum nini W s w wU PE a ca GRRE es c ty R a a gates fetus k IDE WO o dee Ge ea ta daa a a a Rac ae ay Nac a a an cate e a e OW Gal ED a a Qe a aah okay w Dh Ee A A k R AOO LA a A cae A dn cab Ala a om RU w e kl O Set O A UN W a Gir Sah ab Dia G GP ah nih Ql WU O ERs a m R Dab LR E OURO ae x IL p ATA b aa Tee cp cl csl eC a AE A e S A AE U Aa a A a TT Iure a RE dev gah m xcu rcc c r
5. 10 SYSTEM CONTROLS cc I Circuit 5 ene Set Exercise eects ews ee AUTO OFF MANUAL Switch 15 Amp Fuse r Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Table of Contents lt Briggs amp Stratton POWER PRODUCTS Controls by Eaton s Cuilar Hammer TABLE OF CONTENTS FUEL SYSTEM OPTIONS 12 Recontiguring The Fuel System eoe cece uS cede 12 SYSTEM CHECKS amp SETTINGS _ _ r e a r r e 50505005050 00505000222 13 Manual Operation Check No 13 Automatic Operation Check Load Transfer ul 13 Generator Load Tests Full Rated Electrical Capacity And Fuel Consumption _ 13 Stopping The System For Maintenance Lc ccccsii 14 Setting Exercise 14 ENGINE 15 Checking Oil Level I5 Changing the Oil and Oil Filter ee 15 Cleaning or Replacing the Spark Plug 15 Service Air Cleaner I0 l6 Inspect Spark Arrestor Screen 1 l6 Engine Governed ________________________________________________________________________ l6 _ l6 THE CONTROL MODULE ASSEMBLY CMA 17 Fault Detection Conditions 18 Power During Fault Conditions 18 Resetting The Fault Detection System _ _ _ _______
6. Home Standby Generator System Briggs amp Stratton ee Model 1897 1976 amp 1977 7000kW Troubleshooting Information Controls by Eaton s Cutler Hommer Removing The Rotor Inspecting The Rotor Assembly Remove the rotor through bolt It is not possible to check the serviceable condition of a rotor assembly without de soldering the diode and NOTE The rotor is mounted on a tappered engine capacitor IN shaft and sometimes sticks to the engine shaft As an added safety precaution turn the through bolt into NOTE To ensure an accurate reading it may be the threads of the engine shaft by hand to prevent necessary to clean the slip rings with Scotch Brite the rotor from falling or fine emmery cloth 2 While supporting and pulling the rotor with one hand The reading that is obtained by the process shown in figure tap the rotor assembly with a soft mallet until it comes 45 only gives the resistance value of the rotor winding free of the engine shaft Figure 43 Figure 45 Rotor Assembly Dee I KI Figure 43 Removing The Rotor rr It does not show if the diode or the thermal protection device is serviceable The only way to determine if these Unless there are special circumstances there is no reason to components are serviceable is to de solder them from the remove the engine adaptor Figure 44 from the engine electrical circuit of the rotor assembly and check them individually
7. or otherwise damaged electrical cord sets with any generator set Using a defective cord may result in an electrical shock or damage to the test equipment and or the unit LL 20 These units require an adequate flow of cooling air for their continued proper operation Never operate or service any unit while inside any enclosure where the free flow of cooling air into and out of the unit might be obstructed Without sufficient cooling airflow the units quickly overheat damaging the generator and or nearby property Home Standby Generator Systems produce a very powerful voltage that can cause an extremely dangerous electrical shock Avoid contact with bare wires terminals etc Never permit an untrained person to service or assist with the procedures discussed in this guide Never start or stop a unit with electrical loads connected to receptacles and with the connected loads turned ON Start the engine and let it stabilize before connecting any electrical loads Turn OFF and disconnect all electrical loads before shutting down any generator The manufacturer could not possibly anticipate every circumstance that might involve a hazard For that reason warning in manuals and woarnings on tags or decals affixed to the units are not all inclusive Do not handle operate or service a unit with a procedure or method not specifically recommended by the manufacturer This entire book is filled with important s
8. Use only 5W 30 API Service Grade SJ CF or greater synthetic oil Change oil after every 50 operating hours Replace oil filter every 100 operating hours lt Briggs amp Stratton POWER PRODUCTS Controls by Eoton s Cuilar Hammer If you are using this engine under dirty or dusty conditions or in extremely hot weather change the oil more often Use the following instructions to change the oil while the engine is still warm Remove the oil filter cover and the oil drain cover from the sides of the generator enclosure panels Place the oil drain hose into a suitable container Grasp the oil drain fitting and push it in towards the engine Rotate it counterclockwise to its stop and pull the fitting outwards slowly Oil should begin to flow out of the oil drain hose After the oil is drained grasp the oil drain fitting and push in while rotating clockwise until it locks in place Position the oil drain hose in its storage clip Place the oil drain tray on the square tubular frame under the oil filter and remove the oil filter Wipe the filter adapter flange clean with a cloth Coat the o ring of the new filter with fresh clean engine oil Turn the new filter clockwise by hand until the gasket contacts the filter adapter then tighten 1 2 to 3 4 turn more e Service engine with oil to the FULL mark on the dipstick Install and seat the oil fill cap Run the engine for a few minutes Stop the
9. generator Refer to the Briggs amp Stratton Engine Service Manual 272147 to determine the proper method for checking the engine for ignition spark 26 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Low Frequency Five Blinks The low frequency shutdown feature is designed to protect the generator and the devices connected to the protected circuits from an output frequency that is too low The CMA senses a frequency at Pin 8 Wire 466A and Pin 7 Wire 0 NOTE No Load RPM 3750 100 RPM Full Load RPM 3420 100 RPM Full electrical load with all gaseous fuel appliances turned ON If output frequency drops below a minimum for more than a few seconds the CMA will shut down the generator and trigger the diagnostic LED to blink in a set of five blinks This condition may be caused by a failed engine governor by excessive loads on the protected circuits of the house fuel delivery problems engine failure or an failure in the generator wiring Low Frequency Troubleshooting Procedure Verify that the Control Module Assembly CMA is grounded Check engine RPM Set engine RPM to 3750 as specified in the BRIGGS amp STRATTON engine service manual 272147 Clamp on Spark Plug Wire Tach 3750 DIGITAL TACH amp HOURMETER BRIGGS amp STRATTON 19389 e Set AUTO OFF MANUAL swit
10. 111 and 112 connected Repair and or replace any defective wiring or terminals between the terminal ends at the BCA and the utility input terminals in the service disconnect box e Retest for a minimum of 2VDC at the spade connector of Wire 13 coming from the BCA board Test 3A Check The Float Charging System NOTE Depending on the state of charge of a battery a slight current flow indicates that the charging system is working Approximate current values are 033 AMP for a fully charged battery to 750 AMP for a depleated battery Follow the recomendations of your meter s instruction manual Remove the negative battery cable Service amp Troubleshooting Guide Home Standby Generator System E rigga ils bigis Model 1897 1976 amp 1977 7000kW Troubleshooting Information Controls by Eaton s Cutler Hommer Install a DC Amp meter between the negative Test 4 Check The Starter Motor battery terminal and the negative battery cable Figure Whenever the unit is directed to start MANUAL or 26 AUTO the CMA delivers approximately 2VDC from Pin 2 Wire 56 to the starter contactor for about 15 seconds i and repeats the attempt until around 90 seconds of start EC ow aS time have accumulated During the starting attempt the CMA monitors Pin 8 Wire 466A and Pin 7 Wire 0 for a minimum frequency signal This frequency terminates the delive
11. 1976 amp 1977 7000kW Troubleshooting Information POWER PRODUCTS Controls by Eoton s Cuilar Hammer GENERATOR UNIT DISASSEMBLY Preparation 10 Remove the positive battery cable from the ep i 7 ee tarter At this point it is assumed that you already have the roof i the left side panel and the front enclosure panel removed Disconnect the 6 pin connector P 1 from the See page 9 for information relating to removing these generator components 12 Disconnect the wire from the oil pressure sensor Drain engine oil Page 15 3 Disconnect the wire from the oil warmer if so 2 AOM switch OFF equipped and from the harness connector Figure 39 3 Main Circuit Breaker OFF 4 5 AMP fuse OUT Figure 35 Disconnect The Oil Temperature Connector 5 Remove the two 6mm bolts that hold the exhaust tube to the engine Figure 6 Slip the flexible exhaust manifold up and out of the muffer assembly Figure 33B Figure 33 Removing the Exhaust Flex Tube 14 Remove the lower engine mount nuts from all four engine mounts 15 Disconnect the fuel supply hose at the mixer and plug hose 16 Remove the voltage regulator mounting screws N NOTE Carefully note the location of the wires that are connected to the voltage regulator Figure 36 and remove wires from regulator AW SEES A we Figure 36 Voltage Regulator Wiring 7 Remove the two bolts that se
12. Briggs amp Stratton POWER PRODUCTS Controls by Ecton s Cutler Hammer Generator output frequency is directly proportional to engine RPM If frequency gradually increases from 60 Hz and exceeds 72 Hz for five seconds the CMA shuts the generator down and directs the LED to flash in a set of six blinks If the generator output frequency exceeds 75 Hz the CMA shuts the generator down instantly and initiates the LED to flash in a set of six blinks The reason for this latitude in sensing output frequency is that often a governor will hunt for the desired setting This causes variable frequency outputs that are not harmful until they reach the 72 Hz limit Should the governor fail completely the RPM will increase uncontrolled In this case the generator will appear to stall immediately after starting In reality it is shut down when the output frequency reaches harmful levels Over Frequency Troubleshooting Procedure Select MANUAL at the AUTO OFF MANUAL switch and allow engine to stabilize Check engine RPM Set engine RPM to 3750 as specified in the BRIGGS amp STRATTON engine service manual 272147 Clamp on Spark Plug Wire Tach 3750 DIGITAL TACH amp HOURMETER BRIGGS amp STRATTON 19389 Measure voltage and frequency at Pin 8 Wire 66A or Pin 7 Wire 0 and Ground as shown in figure 22 NOTE Follow the Frequency Measurement instructions that apply to the type of meter you ar
13. PEE IT TM JI ommo ommo Pos s Roman hom o nh Moo r opo hon omo sns n n n o mon ho nog modom mom qoem hos mono m n num hom omo D s e mum ho n s n oe e e e nes oh e n homo on om oh ee e m n n m n n m n FN n n m om n mun m n m m n eoe a m n Ne e om s dos e m on m mos m n on n IMMITTO MC T a by aT E MMC quei X A XAR RUNE E EN T eR Ce N amp a eC Re TT I c LU PL IL ELETEL ILIILLLILPPILCDEE TETTE Uu MM oie Alum GB Gat Deck P e dick R di cl ie d Gk W UR diode doch OR MIN IE S s ele RN GRE SAC dame Im Wee dc iR IR ADAC tea SR OR d R O OP di IR dean cage cee DID IR k AR ds Sm OUR UR dr Sh IAE dc deen i ae HERI LC LI LIC IP I ZI ccc cp lc cc ik Oh ccc ccc cd c fc lc cmd c ccc clc cap lc k uk Qp k 5 amp Shop cp c c pc c cac cA ra n mmo ep on mon m n mom oon mor or m Bon somos s n somos n n n ass ns ne n n on is s nu s s s n i nnm s n n n n n on s n T y n Lacu
14. Starter Motor Connections Engine Component Failures 23 Service amp Troubleshooting Guide Home Standby Generator System E rigga AA T m A o D Q n P lt s sv 3 x Model 1897 1976 amp 1977 7000kW Troubleshooting Information by Eaton s Cutler Hammer Inspect the standby unit for any obvious broken or corroded Figure 17 Temporary Manometer Installation electrical connections Starting at the control panel visually inspect wiring and terminals associated with the following components Spark Plug Lead Remove the plug lead and check that the plug is tight in the engine Starter Contactor Fuel Solenoid Generator and Engine Grounds Starter Motor 2 Utility voltage is present at the I TO 14 inches of water in W C LP CMA c 5 to 7 inches of water in W C NG Use caution to avoid personal electrical shock or should be measured under full electrical load with all d to th tem gaseous fuel appliances turned ON If the proper fuel pressure is not present Gain access to the control module assembly see page 7 Repair and or replace fuel delivery system and visually inspect Re test fuel pressure as described above All component connections If fuel pressure is acceptable Check the Fuel Solenoid
15. 7 1976 amp 1977 7000kW Troubleshooting Information 4 Carefully lift the engine generator assembly until it is clear of the cradle Figure 39 Figure 39 Engine Alternator Assembly Suspended 34 extra engine cradle available N NOTE For shop work it is a good idea to have an Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Briggs amp Stratton POWER PRODUCTS Controls by Eoton s Cuilar Hammer Removing Brushes Removing The Alternator The brush assembly is located inside the rear bearing Make sure the engine alternator assembly is set on a assembly sturdy flat work surface Figure 41 Set the stator assembly on the table with the 6 pin CAUTION Do rot setis generator assembly connector up on the plastic end cap or damage will occur 2 Remove the plastic end cover and remove the two mounting bolts that secure the brush holder to the rear bearing carrier Figure 40 Figure 4 Prepairing To Remove The Alternator Figure 40 Removing End Cover amp Brush Holder Assembly na ch ree RTI a ae Lie 8 2 Locate the bolts that attach the generator assembly to the engine adaptor Figure 42 Figure 42 Alternator Mount Bolts mn x LT m y 3 Remove all four bolts 4 Remove the stator assembly 35 Service amp Troubleshooting Guide
16. Repair and or replace any damaged wiring or terminal connections 0 Pin connector on the CMA board While the engine is cranking Reset LED attempt MANUAL start and observe system Check for DC voltage at the fuel solenoid Figure 18 operation Figure 18 Check Fuel Solenoid For DC Voltage If there no obvious electrical faults and the problem PE persists E31 Verify that fuel pressure is available to the fuel solenoid i Install a manometer as illustrated in figure 17 G2 SVO 13 4 Gt LPOBE 1 c veut LRBEZLZAH Paing Hi QJ Hane vasv 7 12VDC should be measured 24 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information If no voltage is present at the fuel solenoid Check for voltage at Pin 3 Wire 14 at the CMA harness connector Figure 19 Harga 2 Eia EN fihi TID E DAY EI ir m yee 7 14VDC should be measured If no voltage is present at Pin 3 Wire 1 4 Verify that there are no other faults BEFORE replacing the CMA circuit board Replace the CMA Circuit Board If voltage is present at the solenoid The fuel solenoid allows fuel pressure to the fuel regulator The regulator delivers fuel to the mixer when a negative atmoshere is created by the intake stroke of the engine piston If fuel and fuel flow are present withou
17. Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Guide lt Briggs amp Stratton POWER PRODUCTS C anbals by Emons MODELS 1897 1976 amp 1977 TROUBLESHOOTING GUIDE VIDA Z77777 276142GS Service amp Troubleshooting Guide Home Standby Generator System aa Model 1897 1976 amp 1977 7000kW Table of Contents Controls by Eaton s Cuilar Hammer TABLE OF CONTENTS SAFETY INFORMATION ee 5 In the Interest of Safety eee 5 Safety Alert Symbols LLL LLL LLL DL LLL aaa aa aa 5 Safety 6 SPECIFICATIONS 8 Generator ee SP sr ee rere eee 8 ENGINE eo no ssf i eS ne ene Es 8 GENERATOR ENCLOSURE eee ne neeenenennenenenennenenenenneneetnee 9 RGOI FROIN A 9 Access Door _________________________________________________________________________ 9 Front Panel Left Side Panel e ne 9 GENERATOR COMPONENTS aaa aa aa 10 Ar C Il enn I0 10 Control Panel I0 Disconnect Box 10 Fipiie MN 10 Exha st ee E 10 Fuel Inlet is uec teile uei I0 Littine POCKET es 10 Oil Fill Cap Dipstick 10 Oil Drain Hose nO ne ss I0 _ eee 10 Unit Data Decal e
18. afety information please read it carefully Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information lt Briggs amp Stratton POWER PRODUCTS Controls by Eaton s Cuilar Hammer MODELS 1897 1976 amp 1977 TROUBLESHOOTING INFORMATION Service amp Troubleshooting Guide Home Standby Generator System Briggs amp Stratton Po vD r r s n Y Uyo n n D D l Model 1897 1976 amp 1977 7000kW Troubleshooting Information Controls by Eaton s Cutler Hammer SPECIFICATIONS SPECIFICATIONS Model 1897 1976 amp 1977 Generator Rated Maximum Power LP 0 7000 kW Rated Maximum Load Current 29 1 Amps at 120 58 3 Amps Rated AC Voltage tette tette 120 240 Volts BROS UW SC SBN 6 NRI I TR 60 Hz at 3600 RPM DET Single Phase Power Facto orcs aces a E 1 0 NG Fuel Supply 5 7 in W C 127 178mm LP Fuel Supply Pressure u 11 14 in W C 279 356mm Normal Operating Range eene tentent 20 F 28 8 C 104 F 40 C Output Sound Develop ct ee MN ME Me 81dBa 23ft 7m at full load Natural gas rating will depend on specific fuel but typical derates are between 1076 to 2076 off the LP gas rating Engine i oe Mr
19. around battery for a long time after battery has been charged Slightest spark will ignite hydrogen and cause explosion You can be blinded or severely injured Battery electrolyte fluid contains acid and is extremely caustic Contact with battery fluid will cause severe chemical burns Do not allow any open flame spark heat or lit cigarette around battery during and for several minutes after charging Wear protective goggles rubber apron and rubber gloves lt Briggs amp Stratton POWER PRODUCTS Controls by Eaton s Cuilar Hammer Fuel and its vapors are extremely flammable and explosive Fire or explosion can cause severe burns or death GASEOUS FUEL SAFETY e Only qualified gaseous fuel techinicians should attempt to service the fuel delivery system e Make sure that propane storage containers are of an approved type and comply with applicable codes standards and regulations e Keep all fuel away from sparks open flames pilot lights heat and other ignition sources e Do not light a cigarette or smoke WHEN OPERATING EQUIPMENT e Make sure a gaseous fuel shut off valve is available for an emergency WHEN TRANSPORTING OR REPAIRING EQUIPMENT e Make sure the fuel shut off valve is OFF e Disconnect spark plug wire e Do Not operate generator in a moving vehicle or watercraft WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK e Store away from furnaces stov
20. ce Manual 272147 for specifications Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information The Control Module Assembly CMA See Generator Enclosure Page 9 for access to the control panel The control module assembly CMA and the battery charge assembly BCA are printed circuit boards that contain the logic circuits that operate amp protect both the generator and the dwelling It is mounted on the back side of the generator control panel Figure 8 Figure 8 CMA amp BCA Location J E j 1 E F 2 a 1 Y E MM Y a i 5 n 4 E en i 8 L L 5 a j 1 rs E Aa I i ha fap I I z X b oU 3 d J i a I S T ENS ip To access the CMA board Remove the four screw securing the control panel to the generator enclosure Fold the panel down in the slots provided for support as shown in figure 9 Figure 9 Control Panel In Its Mounting Briggs amp Stratton POWER PRODUCTS Canals by Eaton s Cutler Hammer The CMA is the control center of the unit Its functions depend on input from various circuits throughout the Home Standby Generator System Before replacing the CMA all other circuits must be tested for proper operation When a failure in the CMA has been determined the CMA must be replaced as a complete board assembly The componen
21. ch to MANUAL and allow engine to start and stabilize Measure voltage and frequency at Pin 8 Wire 66A or Pin 7 Wire 0 and Ground as shown in figure 22 Pin 8 shown Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Figure 22 Voltage And Frequency At Pin 8 Wire 66A And Ground ww 62 62 5 Hz No Load should be measured NOTE Follow the Frequency Measurement instructions that apply to the type of meter you are using Verify that there are no other faults BEFORE replacing the CMA circuit board If frequency and voltage are correct Replace CMA Circuit Board If frequency is not correct Check engine RPM Set engine RPM to 3750 100 as specified in the BRIGGS amp STRATTON engine service manual 272147 If no frequency is measured Check for open Battery Charge Winding Refer to Checking The Battery Charge Winding BCW Through The PI Connector on page 32 Repair or replace as necessary Over Frequency Six Blinks This feature of the Home Standby Generator System protects devices that are wired into the protected circuits by shutting down the generator if it runs faster than the governed RPM limit 3750 RPM The control module assembly CMA senses frequency Output at Pin 8 Wire 66A and Pin 7 Wire 0 27 lt
22. circumstances that are outside the capacity of the CMA to protect are also provided later in this section Power During Fault Conditions Whenever the Home Standby Generator System is in an uncorrected fault condition the automatic transfer switch defaults to UTILITY power when available This means that when UTILITY power is available it will automatically be applied to all the circuits in the dwelling Resetting The Fault Detection System An operator or a technician must reset the fault detection system each time it is activated Set the AUTO OFF MANUAL in the OFF position for 30 seconds or more Set the AUTO OFF MANUAL in the AUTO position If the fault is not corrected it will be detected again and the unit will start and shut down At this point the LED will flash with the corresponding number of blinks Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Generator AC Connection System A single phase three wire AC system is used in the Home Standby Generator System The stator assembly consists of a pair of stationary windings with two leads brought out of each winding The two windings are connected together in series resulting in a fixed 120 240VAC 60Hz output Stator output leads 1 and 44A are two hot leads The junction of leads 22 and 33 form the neutral lead 22A Figure 11 Figure System AC Connectio
23. cure the muffler heat shield assembly and set the heat shield aside 8 Using a 10mm wrench disconnect the negative battery cable from the battery and secure in such a way as not to allow it to come in contact with the terminal 9 Disconnect the other end of the negative cable from the engine block Figure 34 Figure 34 Negative Battery Cable at Engine Block 7 Push the wire harness for the regulator through the channel in the air duct into the center of the air plenum Controls by Eaton s Cutler Hommer Engine Alternator Removal Fabricating Lifting Hardware Depending on the type of lifting mechanism you have available it may be necessary to fabricate a pair of lifting eyes to remove the engine alternator assembly from the mounting cradle If this is the case fabricate two lifting eyes according to the following specifications Figure 37 Figure 37 Lifting Eye Specifications Material 3125 Steel penp Line Remove the nut from the upper portion of the engine mount that is located forward of the engine starter as shown in figure 38 Figure 38 Lifting Eyes Installed 3 S gt J am 1 1 n 2 Install fabricated mounting brackets 3 Repeat this process for the engine mount that is located behind the oil filter Service amp Troubleshooting Guide Home Standby Generator System Briggs amp Stratton ee ae Model 189
24. d above In addition while taking these measurements make sure that all gaseous fuel appliances in the dwelling are turned ON If any parameter is outside the ranges mentioned refer to BRIGGS amp STRATTON engine service manual 272147 for governor adjustment procedures Check generator output between one of the generator connections and the neutral lug then between the other generator connection and the neutral lug In both cases the voltage reading should be about 120 Let the Home Standby Generator System run at full rated load for 20 30 minutes Listen for unusual noises check for excessive vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc Turn the main distribution circuit breaker ON NOTE If the unit has run for 5 minutes or more it will transfer the load back within 10 seconds If the unit has run for less than 5 minutes it will continue to run for approximately 5 to 6 minutes to warm up the engine and then transfer the load back to utility power Model 1897 1976 amp 1977 7000kW Troubleshooting Information About one minute after re transfer the engine will shut down Set the generator s main circuit breaker to OFF e Set the AUTO OFF MANUAL switch to OFF Stopping The System For Maintenance To disable the unit from starting automatically Ensure that the utility power is ON and supplied to the UTILITY CONNECTION lugs of the tra
25. e using If frequency is correct Verify that there are no other faults BEFORE replacing the CMA circuit board Replace CMA Circuit Board If frequency is not correct Check engine RPM Set engine RPM to 3750 as specified in the BRIGGS amp STRATTON engine service manual 272147 Service amp Troubleshooting Guide Home Standby Generator System EEE nm Model 1897 1976 amp 1977 7000kW Troubleshooting Information Controls by Eaton s Cutler Hammer Figure 23 Troubleshooting An Engine That Fails to Crank e Test 2 Test 3 nee non Check Fuse ia T Troubleshoot ond ve NO Position NO NO iiie YES lt NO p NO YES Float Charging System YES ee YES Test 5 Check Starter gt gt YES NO Contactor j NO tx nd I tu NO p NO YES q Check CMA ves Repair Qo nome i Repair END vs 28 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Troubleshooting An Engine That Fails To Crank Refer to figure 23 Test Check AOM Switch Position The AOM switch refers to the AUTO OFF MANUAL switch which is located on the generator control panel Check LED if installed Gain access to the control panel see page 9 and check to make sure th
26. e AUTO OFF MANUAL switch is not in OFF position Test 2 Check Fuse Remove the fuse next to the AOM switch in figure 24 and inspect Figure 24 AUTO OFF MANUAL Switch amp 15 Amp Fuse CIRCUIT BREAKER AUTO OFF MANUAL Replace if necessary and attempt to start by selecting MANUAL at the AOM switch Test 3 Troubleshoot The Float Chargin System Remove the 5 AMP fuse Remove Wire 13 White from the connector at the 5 AMP fuse e Measure for a minimum of 2VDC at the spade connector coming out of the Battery Charge Assembly Wire 13 White f a minimum of I2VDC is measured at the connector Reconnect the spade connector to the 5AMP fuse Remove Wire 13 from the starter contactor Measure for a minimum of I2VDC at the terminal end of Wire 13 Briggs i amp Stratton POWER PRODUCTS Controls by Eoton s Cuilar Hammer If proper voltage is not present at the terminal end Check all interconnecting wiring and terminal ends to the starter contactor and repair replace any faulty components Measure for utility voltage at spades J8 and J7 with Wires 111 and 112 connected Figure 25 Figure 25 240VAC Input At Battery Charge Assembly If utility voltage is present at spades J8 and J7 with wire s 111 and 112 connected Replace the Battery Charge Assembly BCA If 240VAC is not present at spades J8 and J7 with wire 4s
27. e are no other faults Failed Ignition BEFORE Failed and or Damaged Wiring Clogged fuel regulator atmospheric vent replacing the CMA circuit board Replace the CMA board Troubleshooting Procedure Reinstall the 15 Amp fuse roubleshooting r rocedure Reset the fault indication LED by selecting OFF at the Reinstall utility voltage at the disconnect box AUTO OFF MANUAL switch for 30 seconds r DESAIN e Set the AUTO OFFIMANUAL switch to MANUAL and e Set AUTO OFF MANUAL switch to AUTO Observe system operation Remove utility power and verify system operation Two possible conditions will exist Reinstall all enclosure panels and return system to Engine cranks but fails to start See below automatic standby configuration Engine fails to crank Go to page 28 Engine Cranks But Fails To Start Engine Fails To Start Four Blinks Ensure that adequate fuel is available to operate the Home This is a feature of the control module assembly CMA that Standby Generator System prevents the standby unit from damaging itself by continually Inspect the fuel supply to verify that the main supply is attempting to start in spite of a problem that is beyond the ON CMA s ability to monitor Whenever the unit is directed to start MANUAL or AUTO the CMA delivers I2VDC from Inspect fuel supply plumbing for any shut off valves that Pin 2 Wire 56 to the starter contactor for abbroximate
28. e the three screws that retain the panel to the unit base 2 Remove the three screws that secure the panel to the battery and control panel box 3 Lift the left side panel from the unit base To Install Left And Front Panels Guide left side panel into base and replace screws 2 Guide front panel into base and retaining clips 3 Reinstall retaining screws 1 Left Side Panel G Roof 4 Front Panel 1 Disconnect 2 Electrical Cable G Fuel Connection 4 Oil Drain Cover To Install Access Door and Roof Guide bottom of access door into base 2 Push access door until it is flush with sides 3 Replace door screw 4 Replace roof and screws Service amp Troubleshooting Guide Home Standby Generator System O_o Model 1897 1976 amp 1977 7000kW Troubleshooting Information Controls by Eaton s Cutler Hammer GENERATOR COMPONENTS Figure 3 Generator Components Generator is shown with roof plastic access door and control panel door removed for clarity Air Cleaner Uses a dry type filter element and foam Exhaust Port High performance muffler lowers engine precleaner to protect engine by filtering dust and debris out of noise to comply with most residential codes intake air Fuel Inlet Attach appropriate fuel supply to generator 2 Battery 12 VDC 33 Amp Hour sealed battery provides here power to start the engine The batte
29. engine and check for oil leakage around the oil filter Recheck oil level Cleaning or Replacing the Spark Plug Replace the plug every year Use the recommended spark plugs gapped at 0 030 in 0 76 mm Remove the roof as described on page 9 Remove the cover over the generator control panel and remove the 15 AMP fuse Pull the spark plug wire off of the spark plug Clean around the spark plug and remove it from the cylinder head Clean off carbon deposits on the spark plug electrode using a wire brush or commercial solvent Do not blast clean Ensure that the plug gap is set as recommended lt Briggs amp Stratton POWER PRODUCTS Controls by Eaton s Cuilar Hammer Install the correctly gapped spark plug into the cylinder head Torque to 15 Ib ft Reinstall the spark plug wire securely Replace the 15 AMP fuse Set the AUTO OFF MANUAL switch to MANUAL The engine should start and run Shut the engine down by selecting OFF at the AUTO OFF MANUAL switch Set the AUTO OFF MANUAL switch to AUTO to return the generator to standby mode Replace the protective cover over the generator control panel Replace the roof Service Air Cleaner The engine s air cleaner is one of the most important areas to maintain The engine will not run properly and will be damaged if it is run with a dirty air cleaner system Use only genuine BRIGGS amp STRATTON parts Clean the fil
30. er 19464 Measure the resistance value between pin 5 and pin 6 at the PI connector Figure 31 Figure 31 Measure Battery Winding BCW Compare the values with the stator resistance chart listed at right Checking Excitation Winding DPE at the Voltage Regulator Remove the two screws that secure the voltage regulator to the airduct Remove Wire 2 Blue and Wire 6 Red from the voltage regulator With an appropriate volt ohm meter BRIGGS amp STRATTON multimeter 19464 Insert one lead into the spade connector of each wire Figure 32 Figure 32 Measure Excitation Winding DPE DE Compare the values with the stator resistance chart listed at right Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Checking Rotor Winding NOTE It is necessary to remove the stator from the engine adaptor in order to measure the rotor winding With an appropriate volt ohm meter BRIGGS amp STRATTON multimeter 19464 Touch one lead to each slip ring Compare the values with the rotor resistance chart listed below Stator Resistance Part No 19309 AGS 20 26 2 06 2 5 16 21 BE Rotor Resistance Unit Part No 1897 1976 1977 7kW 192171GS 7 5 9 3 22 Service amp Troubleshooting Guide Home Standby Generator System Briggs amp Stratton Model 1897
31. es water heaters clothes dryer or other appliances that have pilot light or other ignition source because they can ignite fuel vapors The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kVV Safety Information Running engines produce heat Temperature of muffler and nearby areas can reach or exceed 150 F 65 C Severe burns can occur on contact Do not touch hot surfaces e Allow equipment to cool before touching e This generator does not meet U S Coast Guard Regulation 33CFR 183 and should not be used on marine applications e Failure to use the appropriate U S Coast Guard approved generator could result in bodily injury and or property damage Safety Practices LLI Do not attempt to modify the unit or use it for any application it was not designed for If you have any questions about your generator s application ask your dealer or consult the factory LL Read these procedures carefully and become familiar with your Home Standby Generator System Know its applications its limitations and any hazards involved pa Never handle any kind of electrical cord or device while standing in water while barefoot or while hands or feet are wet W e Do not use worn bare frayed
32. ing the special tool 19570 remove the existing jet from the lower chamber of the mixer inlet Reinstall the brass cap can deliver fuel to the generator at an inlet pressure Install the LP jet 4 with the same tool between 11 and 14 inches water column including Replace the 3 4 brass any other appliances using the same fuel supply at the same time Figure 6 Converting Carburetor To Use LP Fuel IMPORTANT Ensure that your LP fuel system To reconfigure the fuel system for LP use Shut OFF gas line Gain acces to the unit control panel as described on page 9 e Set the AUTO OFF MANUAL switch to OFF Set the generator s main circuit breaker OFF e Remove the 15 Amp fuse Figure 5 Removing The Exhaust Enclosure Panel Reinstall the front enclosure panel Reinstall the 15 Amp fuse Set the generator s main circuit breaker ON e Set the AUTO OFF MANUAL switch to AUTO Reinstall access door Reinstall the roof The system is now ready to operate using liquid propane LP fuel NOTE To purchase the conversion kit contact figure 5 A B amp C your BRIGGS amp STRATTON source of supply 12 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information lt Briggs amp Stratton POWER PRODUCTS Controls by Eoton s Cuilar Hammer SYSTEM CHECKS amp SETTINGS Operati
33. ion still exists the engine will start and shut down after about 20 seconds The LED will again flash in a set of two blinks Low Oil Pressure Troubleshooting Procedure Set the AUTO OFF MANUAL switch to OFF Set the generator circuit breaker to OFF e Remove the 15 Amp fuse Remove utility voltage at the disconnect box e Remove 10 connector from the CMA board Remove Wire 85 from LOP switch Figure 16 Figure 16 Measure Wire 85 From PSI Switch Measure for short to ground on Wire 85 If a short is detected Repair and or replace wiring as necessary If no short is detected Remove oil pressure switch and install oil pressure gauge 1 8 NPT Re install connector at CMA board e Re install 15 Amp fuse Set the AUTO OFF MANUAL switch to MANUAL The engine should start and run If oil pressure is low Refer to BRIGGS amp STRATTON engine service manual 272147 for repair procedures NOT E Oil Pressure Q 70 F 21 C 10 50 PSI 0 7 3 5 Bar If oil psi is OK and no short to ground exists Replace oil pressure switch Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information lt Briggs amp Stratton POWER PRODUCTS Controls by Eoton s Cuilar Hammer If switch opens with oil pressure and no short to ground Clogged Engine Air Filter Verify that ther
34. leshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information NOTE SET EXERCISE will only work if the unit is in the AUTO mode and this exact procedure is followed The exerciser will need to be re set if the 12 VDC battery is disconnected if you remove the I5 AMP fuse or you start the unit manually as when the unit is demonstrated If you want to change the day and time the unit exercises simply perform the SET EXERCISE procedure on the exact day and time you want it to take place Engine Maintenance Remove 15 Amp fuse from control 2 panel Disconnect spark plug wires Gf from spark plugs e This will prevent accidental engine start Check fuel lines and fittings frequently for cracks or leaks Replace if necessary Checking Oil Level At recommended service intervals and before placing the Home Standby Generator System in service check the engine oil level as follows e Remove the roof Page 9 The dipstick is incorporated with the oil fill cap e Remove the cap and wipe the dipstick clean with a cloth Insert dipstick fully and seat the cap e Remove and check oil level If oil level is low slowly add recommended oil to bring level to Full mark on dipstick Figure 7 Changing the Oil and Oil Filter Figure 7 Oil Dipstick Markings Oil capacity is approximately 1 1 2 quarts 48 ounces or l 6 liters when changing oil and filter
35. ls To Crank sul 28 Test Check AOM Switch ct ace eee 29 29 Test 3 Troubleshoot The Float Charging System ____ 29 Test Check The Float Charging _______________________________________ 29 Test 3B Check 30 Test 4 Check The Starter Motor 30 Test 5 Check Starter cece eee ene 3 Test 6 Check CMA Board 3 Test 7 Engine Failure isse ne 3l Checking Power Winding Through The Pl Connector s 3l Checking The Battery Charge Winding BCW Through The _ __ 32 Checking Excitation Winding DPE At The Voltage Regulator 32 Checking Rotor VV 32 GENERATOR UNIT DISASSEMBLY cee 33 ______________________________________________________________________________ 33 Engine Alternator Removal eee 34 Fabricating Lifting Hardware 34 Removing Brushes RM 35 Removing The Alternator LLa 35 Removing The Rotor 36 Inspecting The Rotor Assembly oo o o aonn 36 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Safety Information In the Interest of Safety This manual outlines the construction function and servicing procedures of the Briggs amp Stratton Power Products Home Standby Generator System lt is str
36. ly When utility power is restored the generator will shut down and is ready for the next utility power outage e OFF position turns off the generator prevents generator from starting and resets any faults MANUAL position starts the generator It is used for maintenance or diagnostic functions 4 15 AMP Fuse Protects the Home Standby Generator System DC control circuits If the fuse has melted open or was removed the engine cannot crank or start Replace the fuse using only a BUSS AGC 5AMP fuse Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Controls by Eaton s Cutler Hommer FUEL SYSTEM OPTIONS Reconfiguring The Fuel System Locate the mixer and remove the upper brass cap The engine of your Home Standby Generator System is with a large straight tipped screwdriver and the 3 4 factory calibrated to run on natural gas NG With minor cap with the appropriate wrench Figure 6A modifications it can be converted to run on liquid propane f With a small straight tipped screwdriver install the Each Home Standby Generator System is delivered with a supplied plug into the upper chamber Figure 6B conversion kit that includes the plug and jet required to complete the conversion to LP The insertion tool 19570 is available through the Briggs amp Stratton source of supply Us
37. ly may be closed 5 seconds It then pauses for approximately 15 seconds and repeats the attempt until abbroximately 90 seconds of start time have accumulated NOTE Fuel shut off valves are often installed as a discretionary convenience to the owner Therefore the number of shut off valves may vary with each During the starting attempt the CMA delivers 2VDC from installation Be sure to trace the entire fuel supply Pin 3 Wire 14 to the fuel solenoid while monitoring Pin system 8 Wire 66A for a minimum frequency signal The CMA terminates delivery of start voltage to the starter contactor Correct any fuel supply problems If the minimum frequency signal has not been sensed after Purge the fuel supply lines of air the accumulative start time the CMA terminates the engine Reset the fault indication LED by selecting OFF at the cranking cycle and triggers the LED to flash in a set of four AUTOJOFFIMANIDAL switch for 30 seconds blinks Set the AUTO OFF MANUAL switch to MANUAL and This directs the service technician to examine supporting observe system operation systems that could prevent the standby system from f no fuel supply discrepancies are present and engine operating PP P P 5 cranks but fails to start For example EM Gain access to the control panel and engine components Fuel Solenoid Failure see page 9 Fuel Supply Discrepancies Failed Starter Motor Failed
38. n Low Pressure SC Starter Contactor SM Starter Motor SWI Switch AUTO OFF MANUAL SW2 Switch Set Exercise BW Plug Battery Warmer EW Plug Oil Warmer GS Ground Stud Six Pin Connector I7B 133 WHITE 13 4 133 13 15A Figure 14 Wiring Diagram Models 1897 1976 amp 1977 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information 13 WHITE WHITE 0 170 SW2 15 22 E II I UNE n 133 133 170 0 I lA 7 22A 56 14 44A BEA 17A 245 LOP 246 246 BLUE WHITE Je CMA 66A 245 WHITE BLUE IIA 245 WHITE BLUE 20 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Briggs amp Stratton POWER PRODUCTS by Eaton s Cutler Hammer Figure 15 Disconnect Switch amp Junction Box DISCONNECT SWITCH AND JUNCTION BOX 112 e a JCILI 111 112 0 IIA 22A T 240 VAC 133 I7A 245 246 REMOTE STATUS LIGHT POLARITY SENSITIVE 240 VAC UTILITY INPUT 112 M e Gss KG G 0 G 21509 2 SES Gu 0 2 s lt Briggs amp Stratton POWER PRODUCTS C
39. ns VOLTAGE REGULATOR Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information Briggs amp Stratton POWER PRODUCTS by Eaton s Cutler Hammer CMA PINS SCHEMATIC amp WIRING DIAGRAMS Figure 12 Control Module Assembly Connector Pins Functions amp Wire Numbers For Models 1897 1976 amp 1977 CUSTOMER OPTION BATTERY 240VAC BATTERY 92B 93B 92A 93A CHARGER AND AUTO STARTER LOW OIL PRESSURE O 12 VDC BATTERY CHARGER STARTER CONTACTOR 12 VDC L 2 a UTILITY Legend FUEL SOLENOID VALVE 12 VDC n3 Battery Charge Assembly Circuit Breaker MANUAL MODE 4 Control Module Assembly 17A Fuse 15A l JUMPER ENGINE START 5 Fuel Solenoid Switch Low Oil Pressure Closes on Low Pressure arter Contactor 12 VDC WHEN ACTIVE r 6 unm cance SE 73884 Starter Motor GROUND Switch AUTO OFF MANUAL BATTERY CHARGE WINDING s Sui Ret Eai 12 VDC 9 2 Plug Battery Warmer SET EXERCISE Plug Oil Warmer G s REMOTE GROUND round Stud 245 STATUS Polarity Sensitive Six Pin Connector Briggs amp Stratton POWER PRODUCTS Canbals by Eaton s Cuilar Hammer Legend BCA Battery Charge Assembly CBI Circuit Breaker CMA Control Module Assembly FI Fuse 15A FS Fuel Solenoid LOP Switch Low Oil Pressure Closes o
40. nsfer switch Set the AUTO OFF MANUAL switch to OFF Set the generator s main circuit breaker to its OFF position Pull disconnect switch out e Remove the 15 AMP fuse as appropriate to your maintenace needs Setting Exercise Timer The Home Standby Generator System is equipped with an exercise timer that will start and exercise the system once every seven days During this exercise period the unit runs for approximately 20 minutes and then shuts down Electrical load transfer does not occur during the exercise cycle unless a utility power outage occurs A switch on the control panel is labeled SET EXERCISE See item 2 on page 11 The specific day and the specific time of day this switch is pressed is retained by a memory chip on the Control Module Assembly CMA The day and time is then referenced by the chip to automatically initiate the system exercise cycle in seven days To perform the SET EXERCISE procedure Choose the day and time you want your Home Standby Generator System to exercise On that day and time set the AUTO OFF MANUAL switch to OFF Press and hold down the SET EXERCISE switch for two seconds Release the SET EXERCISE switch Set the AUTO OFF MANUAL switch to AUTO Set Exercise is complete As an example if you press the SET EXERCISE switch on Sunday morning at 10 00 AM the unit will run an exercise cycle the following Sunday at 10 00 AM x 60 minutes Service amp Troub
41. o the bottom of the muffler with five sheet metal screws Inspect the assembly every 50 hours of operation or once each year whichever comes first The spark arrester must be maintained in good condition by the owner operator Inspect the spark arrester assembly as follows Remove front panel see page 9 2 Remove the three bolts that secure muffler to bracket 3 Remove the five screws that hold the spark arrestor to the bottom of the muffler There should be little or no accumulated soot on the assembly 4 Replace the assembly if burned torn perforated or otherwise damaged Do not use a defective assembly Consult BRIGGS amp STRATTON Technical Services for assistance in replacing the assembly If screen is not damaged t may be cleaned by gently brushing using a wire or bottle brush Engine Governed Speed CAUTION The engine speed was properly adjusted at the factory and should require no additional adjustment Do not attempt to change engine speed If you believe the engine is running too fast or too slow contact the factory for assistance CHANGING THE ENGINE GOVERNED SPEED WILL VOID THE ENGINE WARRANTY AND WILL ADVERSELY AFFECT SYSTEM OPERATION To assure smooth operation keep governor linkage springs and controls free of debris Valve Lash Valve lash must be checked while engine is cold after every 100 hours of operation Adjust if necessary Refer to the BRIGGS amp STRATTON Engine Servi
42. onal Checks Manual Operation Check No Load Starting the generator for the first time should be done without any electrical loads connected as follows Set the AUTO OFF MANUAL switch to the OFF position Set generator s main circuit breaker to the OFF open position Install the 15 AMP fuse in the control panel Make sure that all fuel shut off valves are open Set the AUTO OFF MANUAL switch to MANUAL The unit will go through its starting cycle z NOTE The Home Standby Generator System may have air trapped in the fuel lines It may take a few minutes to purge the air from the lines before the unit will start Listen for any unusual noises vibrations or other indications of abnormal operation Check for oil leaks evidence of overheating and any other abnormalities while the unit is running When you are satisfied with the operation of the generator Set the AUTO OFF MANUAL switch to OFF The unit should shut down Automatic Operation Check Load Transfer To check the system for proper automatic operation Set the AUTO OFF MANUAL switch to the OFF position Ensure that utility power is connected to the UTILITY CONNECTION lugs of the Automatic Transfer Switch Set the main distribution panel circuit breaker Utility Power to ON e Set the AUTO OFF MANUAL switch on the generator to AUTO The generator is now set for automatic operation Turn OFF the main distribution panel circui
43. ontrols by Eaton s Cutler Hommer Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information TROUBLESHOOTING LED FAULTS Low Oil Pressure Two Blinks The generator unit is equipped with a low oil pressure switch LOP The contacts of the switch are normally closed NC and are held open by engine oil pressure during operation Should the engine oil pressure drop below a safe psi the switch contacts will close creating a connection to ground and the engine will be shut down The following sequence of events takes place during the first 20 second interval after engine startup Low Oil Pressure switch LOP is normally closed NC CMA bypasses LOP switch during initial crank LOP switch opens after engine has started and produces oil pressure The CMA board senses engine is running by monitoring frequency on Pin 8 Wire 466A and Pin 7 Wire 0 Once CMA senses engine is running the CMA looks for a ground on Wire 85 If ground is present on Wire 85 CMA will shut engine down and the remote LED will flash in a set of two blinks To remedy a low oil pressure condition fix any obvious oil leak and or add the recommended oil to the FULL mark on the dipstick See page 15 Reset the Fault Detection system as described on page 18 Start the generator No Load as described on page 13 If a low oil pressure condit
44. ry of start voltage to the starter contactor If the minimum frequency signal has not been sensed after about 90 accumulative seconds of start time the CMA terminates the engine starting cycle Figure 26 Checking Battery Trickle Charge Troubleshooting Procedure 3 gt Reset the fault detection system by selecting OFF at SBS x gt the AUTO OFF MANUAL switch for 30 seconds STORAGE BATTERY SYSTEMS USA E JE E y 3 n Set the generator circuit breaker to the OFF position rdum mid po i A N Select the MANUAL position at the AUTO OFF MANUAL switch and while the start cycle is in progress If a current flow is detected Measure for voltage at the terminal of the starter The float charging system is functioning motor Wire 16 as shown in figure 27 Reconnect the negative battery cable Figure 27 Measure Starting Voltage Attempt to start the generator from the AUTO OFF MANUAL switch by selecting MANUAL If a zero or negative AMP draw is detected Test 3B Check Battery e Set the AUTO OFF MANUAL switch to OFF Remove the 5 AMP fuse Pull disconnect switch at box Disconnect the battery cables Using the approved procedure for your battery tester check the battery s state of charge Recharge the battery if required and retest If battery replacement is required use current BRIGGS amp STRATTON recommended replacemen
45. ry receives float charge to maintain battery when engine is not running Lifting Pocket Provided at each corner for lifting generator G Control Panel Used for various tests operation and maintenance functions See SYSTEM CONTROLS on the C Oil Fill Cap Dipstick Check and fill engine with next page recommended oil here 4 Disconnect Box Convienient junction box for ease of Oil Drain Hose Provided to facilitate changing oil installation Allows you to connect to generator output and disconnect utility input D Oil Filter Filters engine oil to prolong engine life 5 Engine Label Stamped top of valve cover 2 Unit Data Decal Identifies unit by serial number Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information lt Briggs amp Stratton POWER PRODUCTS Controls by Eoton s Cuilar Hammer SYSTEM CONTROLS Figure 4 Know Your Control Panel Circuit Breaker Protects the system from over current conditions and must be in the ON position to supply power to the transfer switch Set Exercise Switch Used to set the exercise cycle start time and day of the week Exercise cycle only occurs in AUTO mode AUTO OFF MANUAL This three position switch is as follows AUTO position is the normal operating mode If a utility power outage is sensed the generator will start automatical
46. t breaker Utility Power This is the breaker that supplies utility power to the automatic transfer switch The engine will crank and start once the utility voltage drops and the sensor has timed out After starting the transfer switch will transfer circuit loads to the generator Let the system go through its entire automatic operation sequence Generator output voltage is now supplied to the generator system Contact with energized parts will result in dangerous and possibly fatal electrical shock Proceed with caution Observe the protected circuits and ensure that all anticipated circuits are functioning With the generator supplying power turn ON the main distribution panel circuit breaker Utility Power NOTE If the unit has run for 5 minutes or more it will transfer the load back within 10 seconds If the unit has run for less than 5 minutes it will continue to run for approximately 5 to 6 minutes to warm up the engine and then transfer the load back to utility power About one minute after re transfer the engine will shut down This completes the the test procedures for automatic operation The Home Standby Generator System will now start automaticly when the utility power is lost and will supply power to the protected circuits in the home Generator Load Tests Full Rated Electrical Capacity And Fuel Consumption To test the generator output with electrical loads applied proceed as follo
47. t ignition the gas must be expelled through the exhaust pipe Gas Regulator The gas regulator is an atmospheric zero governor which acts like the float and needle valve in a gasoline carburetor Air flow through the venturi of the carburetor creates a vacuum which acts on the sealed internal side of the gas regulator diaphram Positive atmospheric pressure on the other side of the diaphram then forces it toward the vacuum depressing mechanical levers that pull the valve seat away from the valve which allows fuel to flow as long as the 25 Briggs i amp Stratton POWER PRODUCTS Controls by Eoton s Cuilar Hammer demand persists When the vacuum ceases a spring force pushes on the lever assembly and forces the diaphram and valve seat back against the valve shutting off the fuel flow The easiest way to check the mechanical operation of the fuel solenoid and the fuel regulator is to smell the exhaust during the starting sequence NOTE Fuel should not flow through the gas regulator when the engine is not running Extinguish all sources of fire and do not smoke while performing this inspection M If fuel is detected proceed to Check Ignition Spark page 26 If no indication of fuel is detected at the exhaust pipe during the starting sequence Check the fuel solenoid and or fuel regulator for evidence of mechanical failure you can feel the solenoid click when it activates Remove
48. t part Reconnect the battery cables 9 14 VDC should be measured Reinstall the 15 AMP fuse NOTE Remember that the CMA only delivers Reinstall service disconnect about 2VDC to the starter contactor for 15 seconds Attempt to start the generator from the AOM switch and then rests for 15 seconds by selecting MANUAL If no voltage is present at the terminal of the starter Set Set Exercise switch Page 4 30 Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information lt Briggs amp Stratton POWER PRODUCTS Controls by Entons Cutler Hammer Test 5 Check Starter Contactor If no voltage is measured Check for voltage at Wire 56 at the starter contactor A Verify that there are no other faults as shown in figure 28 BEFORE replacing the CMA circuit board Figure 28 Measuring Coil Terminals of Starter Contactor Replace the CMA circuit board If voltages are present but the starter won t engage Check the NEGATIVE cable for good contact Repair or replace any defects with the grounding cable f starting voltage is present at the starter terminal and you determine that all grounds are good Refer to the BRIGGS amp STRATTON Service Manual 272147 for procedures to check the engine starter Test 7 Engine Failure Refer to the BRIGGS amp STRATTON Ser
49. ter cartridge every 100 hours of operation and the foam filter every 25 hours Clean or replace more often in dusty or dirty conditions CAUTION Never run this equipment without the complete air cleaner system installed on the engine Failure to do so will result in premature engine wear and significantly reduced engine life To service the air cleaner components Remove the roof and access panel as decribed on page 9 2 Remove the 15 amp fuse 3 Set the AUTO OFF MANUAL switch to OFF 4 Unsnap and remove the air filter cover 5 Remove the air filter cartridge and clean lightly tap to remove large particles inspect or replace 6 Remove the foam filter and clean with low air pressure or replace 7 Install foam filter first 8 Install clean air filter cartridge and make sure that the rubber seals are in contact with the mounting all around the filter Engage the two clips of the air filter cover into their slots and close the air filter cover Service amp Troubleshooting Guide Home Standby Generator System Model 1897 1976 amp 1977 7000kW Troubleshooting Information 10 Engage the locking latch of the filter cover and snap shut Replace all filter components if very dirty or damaged Inspect Spark Arrester Screen NOT E Do not use petroleum solvents e g kerosene which will cause the cartridge to deteriorate The engine exhaust muffler has a spark arrester assembly that is secured t
50. the pipe plug that caps the regulator test port and install manometer BRIGGS amp STRATTON 19495 see figure 20 Figure 20 Fuel Regulator With Manometer Installed Vacuum Gauge 2 33 Inchinso II TO 14 inches of water in W C LP 5 to 7 inches of water in W C NG should be measured under full electrical load with all gaseous fuel appliances turned ON lt Briggs amp Stratton POWER PRODUCTS Controls by Eaton s Cutler Hommer If no fuel pressure is measured Replace the fuel solenoid If fuel pressure is measured Refer to figure 21 for the following procedure Figure 21 Testing The Fuel Regulator m T The fuel regulator has two atmospheric vent that balances diaphram pressures Install a 1 8 NPT barb fitting that has a 2 ft length of hose attached to it Plug the other vent hole Gently blow into the hose CAUTION Do not use compressed air The regulator diaphram is easily ruptured While the fuel solenoid is energized this pressure will allow fuel to pass through the regulator This fuel flow will be indicated on the manometer as a decrease in pressure ee If no fuel flow is detected Replace the fuel regulator ee f fuel flow is detected Refer to the BRIGGS amp STRATTON Engine Service Manual 272147 to determine the condition of the gaseous fuel carburetor Check Ignition Spark Turn off the manual fuel valve that supplies fuel to the
51. ts are not serviceable The functions of the CMA board include Set Exercise Timer Manual Start Automatic Start Automatic Cool Down Timer Electronic Fault Detection Automatic Shutdown Protection The CMA board is connected to various generator components through a 10 connector that is mounted directly on the board Figure 10 Figure 10 10 Pin Connector Jotta 8 96255 c1 5 3 C4 5 5 5 6 5 7 i When being directed to measure an electrical value the location procedure of the measurement is shown in the form of a picture The corresponding pin of the connector is shaded in a graphic illustration that is specific to each test being performed A detailed illustration of the entire connector as well as the functions of each individual pin is given on page 19 lt Briggs amp Stratton POWER PRODUCTS Controls by Eaton s Cuilar Hammer Fault Detection Conditions The generator may have to run for long periods of time with no operator present For that reason the Control Module Assembly CMA is equipped with detection circuits that automatically shut the generator down in the event of a potential failure These fault conditions are designed to protect the dwelling as well as the generator unit and include Indication Fault 2 Blinks Low Oil Pressure 4 Blinks Engine Failed to Start 5 Blinks Low Frequency 6 Blinks Engine Over Speed Troubleshooting flowcharts for
52. uctured for use by trained technicians that are working in a properly equipped shop Familiarity with the proper method of using tools measuring equipment and workshop procedures are essential to performing successful maintenance and repair on this equipment Ensure that all specified tools and or equipment are available before attempting to service this equipment For a detailed discussion of the fundamental principles involved with the physics of electrical power generation refer to the Familiarization and Troubleshooting Guide Publication 86262 Revision 3 or later This manual is available through your Briggs amp Stratton Central Distributor Safety Alert Symbols The safety alert symbol M is used to identify safety information about hazards that can result in personal injury A signal word DANGER WARNING CAUTION is used with the alert symbol to indicate the potential severity of injury In addition a hazard symbol may be used to represent the type of hazard DANGER Indicates a hazard which if not avoided will result in death or serious injury A WARNING Indicates a hazard which if not avoided could result in death or serious injury SAFETY INFORMATION CAUTION Indicates a hazard which if not avoided might result in death or serious injury CAUTION When used without the alert symbol indicates a situation that could result in damage to equipment NOTE This notation is
53. used to inform you of a method reference or procedure that could assist with specific operations or decisions HAZARD SYMBOLS AND MEANINGS 0 W Toxic Fumes Electrocution BK ce Hot Surface Chemical Burns Fire Explosion Gh Read Explosive Pressure Goggles w po 5 25 3 Kick Back Disconnect Entanglement Spark Plug Failure to properly ground generator can result in electrocution especially if the generator is equipped with a wheel kit National electric code requires generator to be properly grounded to an approved earth ground Call an electrician for local grounding requirements Briggs amp Stratton POWER PRODUCTS Contals by Eaton s Cutler Hammer Generator produces powerful voltage ull Failure to isolate generator from power utility can result gg in death or injury to electric utility workers due to backfeed of electrical energy e When using generator for backup power notify utility company Use approved transfer equipment to isolate generator from electric utility e Use a ground circuit fault interrupter GFCI in any damp or highly conductive area such as metal decking or steel work Do not touch bare wires or receptacles Do not use generator with electrical cords which are worn frayed bare or otherwise damaged Storage batteries give off explosive hydrogen gas during recharging Hydrogen gas stays
54. vice Manual f intermittent voltage is present at Wire 56 at the 272147 for procedures to check the engine starter contactor with no voltage at the terminal _ connecting Wire 16 Checking Power Winding Through Replace the starter contactor the PI Connector If no voltage presents itself at Wire 56 There are two seperate windings that make up the power output of the stator used in the Home Standby Generator Test 6 Check CMA Board System They share a common connection at pin 3 of the PI Measure the voltage at Pin 2 Wire 56 to ground as connector To check the power windings through the PI shown in figure 29 connector refer to figure 30 and follow the procedure outlined below Figure 29 Measuring Pin 2 Wire 56 And Ground Figure 30 Measure Power Windings With an appropriate volt ohm meter BRIGGS amp STRATTON multimeter 19464 Measure the resistance value between pin 2 and pin 3 at the PI connector Figure 30A Measure the resistance value between pin 3 and pin 4 at the PI connector Figure 30B a 3 C7 Compare the values with the stator resistance chart on page 32 About 9 14VDC should be measured while cranking 3l lt Briggs amp Stratton POWER PRODUCTS Controls by Eaton s Cutler Hommer Checking the Battery Charge Winding BCW Through The PI Connector With an appropriate volt ohm meter BRIGGS amp STRATTON multimet
55. ws Set the generator s main circuit breaker to OFF Set the generator s AUTO OFF MANUAL switch to OFF Turn the main distribution panel circuit breaker Utility Power OFF Set the AUTO OFF MANUAL switch on the generator to AUTO The engine should crank and start immediately Let the engine stabilize and warm up for a few minutes Service amp Troubleshooting Guide Home Standby Generator System lt Briggs amp Stratton O POWER PRODUCTS Controls by Eaton s Culler Hammer e Set the generator s main circuit breaket to ON Generator power is now supplied to the GENERATOR CONNECTION lugs of the automatic transfer switch Contact with energized parts will result in dangerous and possibly fatal electrical shock Proceed with caution e Turn ON electical loads within the protected circuits Continue until the full rated output of the generator is reached e Use an accurate AC voltmeter BRIGGS amp STRATTON Multimeter 19464 to check generator output voltage across the primary load lugs that supply power to the protected circuits Voltage should be greater than 216VAC e Connect an accurate AC frequency meter BRIGGS amp STRATTON Freq Cap Meter 19543 across the primary load lugs of the protected circuits Frequency should be 57 62 5 Hz IMPORTANT Do not proceed until you are certain that generator AC voltage and frequency are correct and within the limits state
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