BRIGGS & STRATTON SERVICE & TROUBLESHOOTING …

Home Generator SystemManual 278382GS Rev A 6/08

BRIGGS & STRATTONSERVICE & TROUBLESHOOTING MANUAL

HOME GENERATOR SYSTEM - 30kW

FORWARDThis manual was written to assist authorized technicians and service personnel with the repair andmaintenance procedures for Briggs & Stratton home standby generator systems. It assumes that personsusing this manual have been properly trained in and are familiar with the servicing procedures for theseproducts, including the proper use of required tools and safety equipment and the application ofappropriate safety practices. Persons untrained or unfamiliar with these procedures or products should notattempt to perform such work.

Proper maintenance and repair is important to safe, reliable operation of the standby system. Thetroubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate forthe models described herein. Alternative methods or procedures may pose risk to personal safety and thesafety and/or reliability of the equipment and are not endorsed or recommended by Briggs & Stratton.

All information, illustrations, and specifications contained in this manual were based on the data availableat the time of publication. Briggs & Stratton Corporation reserves the right to change, alter, or otherwiseimprove the product or the product manuals at any time without prior notice.

Copyright © 2008 Briggs & Stratton Corporation

All rights reserved.

No part of this material may be reproduced or transmitted in any form or by any means, electronic ormechanical, including photocopying or recording by any information storage and retrieval system, withoutprior written permission from Briggs & Stratton Corporation.

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TABLE OF CONTENTS

SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS ...................................... 1

SAFETY MESSAGES .................................................................................................................. 1

ACCESS TO THE GENERATOR................................................................................................. 5

GENERATOR COMPONENTS.................................................................................................... 6

GENERATOR CLEARANCES ..................................................................................................... 9

SYSTEM CONNECTIONS ........................................................................................................... 10

FUEL SUPPLY ............................................................................................................................. 12

ENGINE MAINTENANCE ............................................................................................................ 13

SETTING THE EXERCISE TIMER .............................................................................................. 13

SECTION 2 - TROUBLESHOOTING ................................................................................. 17

SYSTEM CONTROL PANEL (SCP) ............................................................................................ 17

FAULT CODE INDICATIONS ...................................................................................................... 18

STOPPING THE SYSTEM FOR MAINTENANCE ....................................................................... 19

GENERATOR AC CONNECTION SYSTEM................................................................................ 20

(FAULT CODE_1) DEAD UNIT/LOW BATTERY VOLTAGE....................................................... 21

(FAULT CODE_2) LOW OIL PRESSURE ................................................................................... 29

(FAULT CODE_3) LOW OUTPUT VOLTAGE ............................................................................. 33

(FAULT CODE_4) ENGINE FAILS TO START/FAILS TO CRANK ............................................. 39

(FAULT CODE_5) UNDER FREQUENCY................................................................................... 51

(FAULT CODE_6) OVER FREQUENCY ..................................................................................... 54

(FAULT CODE_7) HIGH TEMPERATURE.................................................................................. 55

(FAULT CODE_8) TRANSFER SWITCH FAILURE .................................................................... 58

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SECTION 3- SPECIFICATIONS & REFERENCE.............................................................. 59

SPECIFICATIONS........................................................................................................................ 59

SCHEMATIC ................................................................................................................................ 60

WIRING DIAGRAM ...................................................................................................................... 61

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SECTION 1 - SAFETY, MAINTENANCEAND ADJUSTMENTS

In The Interest Of SafetyThis repair manual contains safety informationthat is designed to:

• Make you aware of hazards associatedwith engines.

• Inform you of the risk of injury associatedwith those hazards.

• Tell you how to avoid or reduce the riskof injury.

The Safety Alert SymbolThe safety alert symbol ( ) is used to identifysafety information about hazards that can resultin personal injury.A signal word (DANGER, WARNING, or CAUTION)is used with the alert symbol to indicate thelikelihood and the potential severity of injury. Inaddition, a hazard symbol may be used torepresent the type of hazard.

DANGER indicates a hazard which, ifnot avoided, will result in death orserious injury.

WARNING indicates a hazard which, ifnot avoided, could result in death orserious injury.

CAUTION indicates a hazard which, ifnot avoided, might result in minor ormoderate injury.

CAUTION: When this signal word is usedwithout the alert symbol, it indicates a situationthat could result in damage to the engine.

• Prior to work, read and understand thesection(s) of this manual that pertain tothe job. Follow all safety warnings.

• Wear suitable eye protection.• When servicing engines or equipment,

prevent accidental starting bydisconnecting control panel fuse, sparkplug wire from the spark plug(s), anddisconnect negative battery cable.

• Disconnect all sources of supply voltagebefore servicing the generator.

WARNINGBefore attempting to service this equipment,read and understand this manual and theoperating instructions of the equipment

Failure to follow instructions could result inDEATH, SERIOUS INJURY (includingparalysis) or property damage.

ExplosionFire Electrical

Shock

ToxicFumes Rotating

Parts

Hot Surface

Auto Start ExplosivePressure Chemical

Burn

Lift Hazard ReadManual

HAZARD SYMBOLS AND MEANINGS

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WARNINGThe engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects, orother reproductive harm.

WARNINGStorage batteries give off explosivehydrogen gas during recharging.Slightest spark will ignite hydrogenand cause explosion.Battery electrolyte fluid contains acidand is extremely caustic.Contact with battery contents willcause severe chemical burns.A battery presents a risk of electricalshock and high short circuit current.

• DO NOT dispose of a battery in a fire.• DO NOT allow any open flame, spark,

heat, or lit cigarette during and for severalminutes after charging a battery.

• DO NOT open or mutilate the battery.• Wear protective goggles, rubber apron,

and rubber gloves.• Remove watches, rings, or other metal

objects.• Use tools with insulated handles.

WARNINGRunning engine gives off carbon mon-oxide, and odorless, colorless,poison gas.Breathing carbon monoxide cancause headache, fatigue, dizziness,vomiting, confusion, seizures,nausea, fainting, or death.

• Operate generator ONLY outdoors.• Install a battery operated carbon monox-

ide alarm near the bedrooms.• Keep exhaust gas from entering a con-

fined area through windows, doors, venti-lation intakes, or other openings.

WARNINGGenerator produces hazardous volt-age.

Failure to properly ground generatorcan result in electrocution.

Failure to isolate generator frompower utility can result in death orinjury to electric utility workers due tobackfeed of electrical energy.

• When using generator for backup power,notify utility company.

• DO NOT touch bare wires or receptacles.• DO NOT handle generator or electrical

cords while standing in water, while bare-foot, or while hands or feet are wet.

• If you must work around a unit while it isoperating, stand on an insulated dry sur-face to reduce shock hazard.

• DO NOT allow unqualified persons or chil-dren to operate or service generator.

• In case of an accident caused by electri-cal shock, immediately shut down thesource of electrical power and contact thelocal authorities. Avoid direct contactwith the victim.

• Despite the safe design of the home gen-erator, operating this equipment impru-dently, neglecting its maintenance, orbeing careless can cause possible injuryor death.

• Remain alert at all times while working onthis equipment. Never work on the equip-ment when you are physically or mentallyfatigued.

• Before performing any maintenance onthe generator, disconnect the batterycable indicated by a NEGATIVE, NEG, or(-) first. When finished, reconnect thatcable last.

• After your home generator is installed, thegenerator may crank and start withoutwarning any time there is a power failure.To prevent possible injury, always set thegenerator’s system switch to OFF ANDremove the 15 Amp fuse BEFORE work-ing on the equipment.

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WARNINGPropane and Natural Gas areextremely flammable and explosive.

Fire or explosion can cause severeburns or death.

• Install the fuel supply system according toN.F.P.A 37 and other applicable fuel-gascodes.

• Before placing the home generator intoservice, the fuel system lines must beproperly purged and leak tested.

• After the generator is installed, you shouldinspect the fuel system periodically.

• NO leakage is permitted.• DO NOT operate engine if the smell of

fuel is present or other explosive condi-tions exist.

• DO NOT smoke around the generator,Wipe up any oil spills immediately. Ensurethat no combustible materials are left inthe generator compartment. Keep thearea near the generator clean and free ofdebris.

WARNINGContact with muffler area can result inserious burns.Exhaust heat/gases can ignite com-bustibles or structures, causing a fire.

• DO NOT touch hot parts and AVOID hotexhaust gases.

• Allow equipment to cool before touching.• DO NOT install the generator closer than

5 feet (1.5m) from any combustibles orstructures with combustible walls having afire resistance rating of less than 1 hour.

WARNINGStarter and other rotating parts canentangle hands, hair, clothing, oraccessories.

• NEVER operate generator without protec-tive housing or covers.

• DO NOT wear loose clothing, jewelry, oranything that may be caught up in thestarter or other rotating parts.

• Tie up long hair and remove jewelry.

CAUTIONInstalling the control panel’s 15A fusecould cause the engine to start.

• DO NOT install this fuse until all plumbingand wiring has been completed andinspected.

CAUTIONExcessively high operating speeds increaserisk of injury and damage to the generator.

Excessive load will cause engine shutdown.

• DO NOT tamper with governed speed.Generator supplies correct rated fre-quency and voltage when running at gov-erned speed.

• DO NOT modify the generator in any way.

CAUTIONAvoid prolonged or repeated skin contact withused motor oil.

• Used motor oil has been shown to causeskin cancer in certain laboratory animals.

• Thoroughly wash exposed areas withsoap and water.

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Standby Safety Practices• This manual contains important safety

messages. Read these carefully andunderstand them before proceeding withmaintenance and repairs.

• Become familiar with the HomeGenerator System. Know itsapplications, its limitations, and anyhazards involved.

• This unit must not be modified for anyapplication other than that for which itwas designed. If you have any questionsabout the home generator System, askthe dealer or consult Briggs and Stratton.

• Never handle any kind of electrical cordor device while standing in the water,while barefoot, or while hands and feetare wet.

• Worn, bare, frayed, or otherwisedamaged electrical cord sets should notbe used with the Home GeneratorSystem. Using a defective cord mayresult is an electrical shock or damage tothe test equipment and/or the unit.

• The Home Generator System requires anadequate supply of cooling air forcontinued proper operation. Never allowthe free flow of cooling air into or out ofthe unit to be obstructed in any way.

• Home Generator Systems producepowerful voltages that can causeextremely dangerous electrical shock.Avoid contact with bare wires, terminals,etc. Never permit an untrained person toservice or assist with the proceduresdiscussed in this manual.

• Never manually start or stop this unit withelectrical loads connected to thereceptacles and turned ON. Start theengine and allow it to stabilize beforeconnecting any electrical loads. TurnOFF and disconnect all electrical loadsbefore shutting down the generator.

• The manufacturer cannot anticipateevery circumstance that might involve orconstitute a hazard. Warnings inmanuals, warnings on hang tags, andlabels affixed to the unit are NOT all-inclusive. Do not handle, operate, orservice the unit using a procedure ormethod that is not specificallyrecommended by the manufacturer.

CAUTIONExceeding generators wattage/amperagecapacity can damage generator and/or electri-cal devices connected to it.

• See Essential Circuits in the Operator’smanual.

• Start generator and let engine stabilizebefore connecting electrical loads.

CAUTIONImproper treatment of generator can damageit and shorten its life, or result in personalinjury.

• Use generator only for intended uses.• If you have questions about intended use,

ask dealer or contact Briggs and Stratton.• Operate generator only on level surface.• Adequate, unobstructed flow of cooling

and ventilating air is critical to correct gen-erator operation.

• The Coolant Fill, Battery, and ControlPanel doors must be installed wheneverthe unit is running.

• DO NOT expose generator to excessivemoisture, dust, dirt, or corrosive vapors.

• Despite the safe design of the home gen-erator, operating this equipment impru-dently, neglecting its maintenance orbeing careless can cause possible injuryor death.

• DO NOT start engine with air cleanerremoved.

• DO NOT insert any objects through thecooling slots.

• DO NOT use the generator or any of itsparts as a step. Stepping on the unit cancause stress and break parts. This mayresult in dangerous operating conditionsfrom leaking exhaust gases, fuel leakage,oil leakage, etc.

• If connected devices overheat, turn themoff and disconnect them from generator.

• Shut off generator if:-electrical output is lost;-equipment sparks, smokes, or emits

flames;-unit vibrates excessively.

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ACCESS TO THE GENERATOR

The home generator is equipped with anenclosure that has four access doors (Figure 1).The doors are named for a significant componentlocated behind them, as follows:

• Control Panel Door• Coolant Fill Door• Battery Door• Exhaust Door

Each Home Standby Generator System isequipped with two identical keys. These keys fitall the doors.NOTE: The Coolant Fill, Battery and ControlPanel doors must be installed whenever the unitis running, or the generator may overheat.

Figure1

Removing An Access Door1. Insert key into lock of access door handle you

wish to open and turn one quarter turncounterclockwise. Remove key. Handle willremain unlocked until you relock it.

2. Grasp door’s handle and turn one quarter turncounterclockwise to open.

3. Coolant Fill door is unlocked in the samemanner. It can be used for adding coolant orengine oil.

NOTE: The enclosure also includes muffler andradiator access panels, used for cleaning thosecomponents. Those panels should remain closedat all other times.

Installing An Access Door1. Mount the door using the notches on the

generator base.2. Close door and turn handle one quarter turn

clockwise.3. Insert key into lock in handle and turn one

quarter turn clockwise. Remove key.

WARNINGContact with muffler area can result inserious burns.

• DO NOT touch hot parts and AVOID hotexhaust gases.

• Allow equipment to cool before touching.

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GENERATOR COMPONENTS

NOTE: Generator is shown with access door removed.A - Oil Dip Stick - Used to check the engine oillevel.B - Engine Label - Identifies engine model andtype.C - Oil Fill Cap - Remove to service the enginewith recommended oil.D - Thermostat - Allows the engine to heat upquickly, and then to keep the engine at a con-stant temperature. It does this by regulating theamount of coolant that goes through the radiator.E - Coolant Recovery Bottle - Provides visualindicator of engine coolant level.F - Oil Filter - Filters engine oil to prolong sys-tem life.G - Oil Drain Plug - Provided to facilitate oilchanging.H - Ignition Coil - Amplifies the voltage of elec-tricity supplied to the ignition system.J - Battery Negative Cable - Cable connectsnegative battery terminal to various electrical cir-cuit and to the engine for starting.K - Oil Pressure Switch - Monitors engine oilpressure when the engine is running. Indicates adrop to below the minimum permissible pres-sure.L - Starter Contactor/Motor - The starter con-tactor supplies the high current

needed to run the starter motor and also pro-vided the force needed to engage the starter.The starter is an electric motor used to turn overthe engine to start it.M - Battery Fuse Holder - Provides over-currentprotection for safe operation of generator battery.Fully insulated and water proof.N - Fuel Solenoid - One inlet and one outlet,electrically controlled to permit and shut off fluidflow.P - Generator Ground - Located on the framebelow the generator circuit breaker cover. Ifrequired by local codes, should ONLY be usedfor a ground rod. See System Control Panel forother Ground locations.R - Unit Data Decal - Identifies unit by modeland serial number.S - Stub In Location - Located in bottom of cir-cuit breaker enclosure for power cable stub inlocation. Panel is removable to allow easy holecutting for conduit.T - Circuit Breaker Enclosure - Equipped withremovable bottom to assist with conduit connec-tion.U - Automatic Voltage Regulator - Access holefor voltage regulator adjustment.V - Control Panel - Used for various tests, oper-ation, and maintenance functions. See SystemControl Panel on the next page.

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NOTE: Circuit breaker cover is removed forillustration purposes.A - Circuit Breaker — Protects the system fromshorts and other over-current conditions. Must be ONto supply power to the Automatic Transfer Switch.B - Generator Neutral Lug — Connection for neutral.Neutral is not bonded to ground or generator.C - Set Exercise Button — Used to set the exercisecycle start time and day-of-the-week. Must be reset ifthe fuse is removed or the battery is disconnected.D- Manual Over-Ride Button — With the systemswitch in AUTO position, push the manual over-rideswitch to start the generator. To turn off the generator,push and hold the manual over-ride switch again untilengine stops.E - 15 Amp Fuse — Protects the home generator DCcontrol circuits. If the fuse has ‘blown’ (melted open) orwas removed, the engine cannot crank or start.F - System Switch — This two-position switch is themost important control on the system and is used asfollows:

• “AUTO” position is the normal operatingposition. If a utility power outage is sensed,the system will start the generator. Whenutility power is restored, AUTO lets theengine stabilize internal temperatures, shuts

off the generator, and waits for the next utility power outage.

• “OFF” position turns off runninggenerator, prevents unit from startingand resets any detected faults.

G - Digital Display — Displays the total number ofhours the generator has been running and fault codes.Used to schedule maintenance tasks and fortroubleshooting operational problems with the homegenerator. All fault conditions are described in FaultDescription System.H - Ten Pin Connection — Low Voltage connectionto signal fault contacts, transfer switch communication,remote LED and auxiliary 12VDC power are made to aremovable ten-pin connector plug.J - Generator Ground Lug — Located next to thecircuit breaker and should meet most codes,standards, and regulations.K - Utility Circuit Connection — Delivers power tothe generator’s circuit board (within internal batterytrickle charge) and water heater. When the power onthese leads is lost, the generator will start. Fuseprotected. Replace the fuse(s) only with identicalfuse(s).L - Generator AC Lugs — Connection for generatorload(s).

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NOTE: Generator is shown with access doorremoved.A - Over Temperature Switch - Switch for auto-matically making or breaking an electrical circuitat predetermined temperature. Will signal thesystem control panel to shut down the generatorwhen the engine coolant reaches a critical level.

B - RPM Sensor - A permanent magnet built intothe sensor provides a magnetic field at the baseof the sensor. As each tooth of the flywheelpasses through the magnetic field, a signal (volt-age pulse) is generated. The engine control unituses this to monitor engine speed to maintain aspecific generator frequency.

C - Air Cleaner - Protects engine by filtering dustand debris out of intake air.

D - Alternator Data Plate - Lists alternator dataspecific to the Marathon alternator assembly.

E - Battery - Stores and supplies electricalenergy. The manufacturer does not supply thebattery.

F- Engine Warmer - An electric heater thatheats the engine by keeping the engine coolantwarm to ease starting in cold weather. Con-nected to utility power and fully automatic.

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GENERATOR CLEARANCES

General Location Guidelines• Install the unit outdoors ONLY.• Place the unit on a prepared concrete

slab that is flat, level, and has provisionsfor water drainage.

• Install the unit in a location where sumppump discharge, rain gutter downspouts, roof run-off, landscape irrigation,or water sprinklers will not flood the unitor spray the enclosure and enter any airinlet or outlet openings.

• Install the unit where the location of anyservices such as phone, electrical, fuel,air conditioning, irrigation, includingcovered, concealed and undergroundservices will not be affected orobstructed.

• Install the unit where air inlet and outletopenings will not become obstructed byleaves, grass, snow, sand, etc. Ifprevailing winds will cause blowing or

drifting you may need to construct awindbreak to protect the unit.

• Install the generator as close as possibleto the transfer switch and fuel supply toreduce the length of wiring, conduit, andpiping.

IMPORTANT: Laws or local codes may regulatethe distance to the fuel supply.

The Minimum clearances from aerial view ofgenerator (A) to combustible (C,D) materials isshown in Figure 1.

• These distances are provided to givegenerator location guidance relativeONLY to combustibles, generatorcooling, and maintenance.

• The minimum distances in the figure areas shown. All four sides of the generatorcannot be enclosed or restricted, even ifthe minimum distances are maintained.DO NOT connect (C) to (D).

• A roof cannot be constructed over the topof the generator.

• Exhaust (B) is directed out the top of thegenerator and must not be allowed toaccumulate.

WARNINGRunning engine gives off carbon mon-oxide, and odorless, colorless, poi-son gas.Breathing carbon monoxide cancause headache, fatigue, dizziness,vomiting, confusion, seizures, nau-sea, fainting, or death.

• Operate generator ONLY outdoors.• Install a battery operated carbon monox-

ide alarm near the bedrooms.• Keep exhaust gas from entering a con-

fined area through windows, doors, venti-lation intakes, or other openings.

WARNINGExhaust heat/gases can ignite com-bustibles or structures, causing a fire.

• DO NOT install the generator closer to 5feet (1.5m) from any combustibles orstructures with combustible walls having afire resistance rating of less than 1 hour.

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SYSTEM CONNECTION

Low Voltage (LV) connections to signal fault contacts, transfer switch communications, remote LED andauxiliary 12VDC power are made to a removable ten-pin connector plug. Compare this illustration with thelocation of these important connections:

A - 10 Pole Connector PlugB - Fault Contacts — Use NO, COM and NC for operating a siren, light, optional GenAlert, etc. to alertyou in case of a fault. Contacts reverse state (NO goes to NC and vice versa) upon a fault condition.C - Transfer Switch Communication — Connects to transfer switch control board for communicationinterface.D - Remote LED Output — Used to connect to the remote LED supplied with the generator. The remoteLED will turn on and off in a series of blinks if certain faults are detected in the generator.E - +12Volt DC, .5 Amp Output — Internal auxiliary power supply.

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GENERATOR AC CONNECTIONSYSTEM

A single-phase, three-wire AC connectionsystem is used on the home generator. Thestator assembly consists of a pair of stationarywindings with two leads brought out of eachwinding. The junction of leads T2 and T3 formsthe neutral lead, as shown schematically and aswiring diagram below. A complete schematic andwiring diagram can be found later in this manual.NOTE: Neutral is not bonded to ground atgenerator.

Grounding the GeneratorGround the home generator per applicablecodes, standards and regulations. There are twogenerator Ground lug locations. The one insidethe alternator junction box next to the circuitbreaker is the primary lug and should meet mostapplications. The second Ground lug is locatedon the frame below the generator circuit breakercover, and should ONLY be used for a groundrod located at the generator, if required by localcodes. See Controls for location.

Utility Circuit Connection“240V Utility” leads must be routed in conduit.The “240V Utility” leads deliver power to thegenerator’s circuit board and water heater. Thispower also charges the battery. When power onthese leads is lost, the generator will start.

Fault Detection SystemThe generator may have to run for long periodsof time with no operator present. For that reason,the system is equipped with sensors thatautomatically shut down the generator in theevent of potentially damaging conditions, suchas low oil pressure, high water temperature, overspeed, and other conditions. Refer to FaultDetection System for more detailed information.

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FUEL SUPPLYDepending on the generator model number, thehome standby generator was manufactured andshipped to run on natural gas or liquid propanevapor. No matter which type of fuel the generatorwas manufactured to run on, it can be fieldconverted to operate on either type of fuel. Whentroubleshooting, engine performance isdependent on receiving the specific pressureand volume of fuel under varying load conditionswith all gas appliances turned on and operating.For fuel consumption and pressurespecifications, consult the installation manual.For proper engine function, factors that areinherent to each of these fuels, your location andthe duration of possible utility interruptions areimportant considerations in the following fuelguidelines:

• Use clean, dry fuel, free of moisture orany particulate material. Using fuelsoutside the following recommendedvalues may cause performanceproblems.

• For engines set up to run on propanevapor (LP), commercial grade HD5propane with a minimum fuel energy of2500 BTUs/ft3 with maximum propylenecontent of 5% and butane and heaviergas content of 2.5% and minimumpropane content of 90%.

Power Decrease at High Altitude or HighTemperature

Air density is less at high altitudes, resulting inless available engine power. Specifically, enginepower will decrease 3.5% for each 1,000 feet(300 meters) above sea level and 1% for each

10F (5.6C) above 77F (25C). These factors mustbe considered when determining total generatorload.



• The home generator is equipped with anautomatic safety gas “fuel shut-off” valve.

• DO NOT operate the equipment if the “fuelshut-off” valve is missing or inoperative.



• Install the fuel supply system according toN.F.P.A 37 and other applicable fuel-gascodes.

• Before placing the home generator intoservice, the fuel system lines must beproperly purged and leak tested.

• After the generator is installed, you shouldinspect the fuel system periodically.

• NO leakage is permitted.• DO NOT operate engine if the smell of

fuel is present or other explosive condi-tions exist.

• DO NOT smoke around the generator,Wipe up any oil spills immediately. Ensurethat no combustible materials are left inthe generator compartment. Keep thearea near the generator clean and free ofdebris.

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SETTING THE EXERCISE TIMERThe home generator is equipped with anexercise timer that will start and exercise thesystem once every seven days. During thisexercise period, the unit runs for approximately20 minutes and then shuts down. Electrical loadtransfer DOES NOT occur during the exercisecycle (unless an utility power outage occurs).A button on the control panel is labeled “SetExercise” (see System Control Panel). Thespecific day and the specific time of day thisbutton is pressed is programmed into the controlboard memory. This date and time is then usedto automatically initiate the system exercisecycle. The “Set Exercise” legend on the controlpanel will flash until the set exercise cycle is set.To perform the Set Exercise procedure:1. Choose the day and time you want your home

generator to exercise.2. On that day and time, press and hold down the

“Set Exercise” button for three seconds.NOTE: “SET EXERCISE” will flash until thebutton is pressed for three seconds, then “SETEXERCISE” will illuminate for 5 seconds, andfinally turn off.3. The unit will then start and run it’s 20 minute

exercise cycle.For example, if you press the “Set Exercise”button on Sunday morning at 10:00 AM, the unitwill run an immediate exercise cycle and anexercise cycle will occur every following Sundayat 10:100 AM (+/- 1/2 hour).NOTE: “Set Exercise” will only work if the unit isin the Automatic mode and this exact procedureis followed. The exerciser will need to be re-setwhenever the 15 Amp fuse is removed orchanged, or if the 12 Volt DC battery isdisconnected.If you want to change the day and time the unitexercises, simply perform the “Set Exercise”procedure at the exact weekday and time youwant it to take place.

GENERATOR MAINTENANCE

Generator maintenance consists of keeping theunit clean. Operate the unit in an environmentwhere it will not be exposed to excessive dust,dirt, moisture or any corrosive vapors. Cooling airlouvers on the enclosure must not becomeclogged with snow, leaves, or any other foreignmaterial.Check the cleanliness of the unit frequently andclean when dust, dirt, oil, moisture or otherforeign substances are visible on its exterior/interior surface.NOTE: DO NOT use direct spray from a gardenhose to clean generator. Water can enter theengine and generator and cause problems.

Engine MaintenanceAn engine manual was packaged with thissystem. Please refer to it for all engine-relatedmaintenance topics. However, proper enginecooling and lubrication are so important we alsoreference them.

Engine OilThe system is filled with the recommended non-synthetic oil (API SL 10W-30W). This allows forproper system operation in a wide range oftemperature and climate conditions.NOTE: Refer to the engine operator’s manual forthe recommended oil change intervals.Shown here is the oil drain location (B) and theoil filter (A).

Figure2

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Changing Engine Oil

KEEP OUT OF THE REACH OF CHILDREN.DON’T POLLUTE. CONSERVE RESOURCES.RETURN USED OIL TO COLLECTIONCENTERS.1. Put SYSTEM switch in OFF. Remove 15 Amp

fuse. Disconnect negative battery cable fromnegative battery terminal.

2. Change oil while the engine is still warm fromrunning, as described in the engine operator’smanual.

To fill your engine with oil:Follow the oil grade recommendation and oil fillinstructions given in the engine operator’smanual.To make the task of adding oil more convenient,we recommend the use of a funnel attached tothe length of tubing long enough to reach fromthe Coolant Fill door to the oil fill opening on theengine valve cover. Recheck oil level,reconnectbattery, install fuse, put in AUTO and resetexercise timer when complete.

Engine Coolant SystemWith the engine cold, check the coolant level inthe coolant recovery bottle, seen inside theControl Panel door. Maintenance instructions forengine coolant are found in the engine operator’smanual.

BATTERYCharging the BatteryIf it is necessary to charge the battery, proceedas follows:1. Set generator’s system switch to OFF.2. Remove 15 Amp fuse from control panel.3. Disconnect negative battery cable to negative

battery terminal (indicated by NEGATIVE,NEG, or (-)).

4. Charge battery with a battery charger at 2Amps until battery holds 12 Volts.

NOTE: With the battery installed and utilitypower available to the transfer switch, the batteryreceives a trickle charge whenever the engine isnot running. It may take up to 72 hours to fullycharge a discharged battery with the tricklecharge. The trickle charge is not able to rechargea battery that is completely discharged.

CAUTIONAvoid prolonged or repeated skin contact withused motor oil.

• Used motor oil has been shown to causeskin cancer in certain laboratory animals.

• Thoroughly wash exposed areas withsoap and water.

NOTICEAny attempt to crank or start the engine beforeit has been properly serviced with the recom-mended coolant or oil will result in equipmentfailure.

• Refer to Maintenance in the Operator’sManual and engine manual for coolantand oil fill information.

• Damage to equipment resulting from fail-ure to follow this instruction will voidengine and generator warranty.

NOTICEFailure to disconnect the negative batterycable will result in equipment failure.

• DO NOT attempt to jump start the battery.• Damage to equipment resulting from fail-

ure to follow this instruction will void war-ranty.

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5. Connect negative battery cable to negativebattery terminal (indicated by NEGATIVE,NEG, or (-)).

6. Ensure hardware on both positive andnegative battery terminals is secure.

7. Reinstall 15 Amp fuse in control panel.

8. Set generator’s system switch to AUTO.9. Reset exercise timer. See Setting Exercise

Timer.

Servicing the BatteryIf it is necessary to service the battery, proceedas follows:1. Set control board System switch to OFF.2. Remove 15 Amp fuse from control panel.3. Service or replace battery as required.4. Connect red battery cable to battery positive

terminal (indicated by POSITIVE, POS, or (+)).5. Connect negative battery cable to negative

battery terminal (indicated by NEGATIVE,NEG, or (-)).

6. Ensure hardware on both positive andnegative battery terminals is secure.

7. Reinstall 15 Amp fuse in control panel.8. Set generator’s system switch to AUTO.9. Reset exercise timer. See Setting Exercise

Timer.

To Clean the Generator

• Use a damp cloth to wipe exteriorsurfaces clean.

• Use a soft bristle brush to loosen cakedon dirt, oil, etc.

• Use a vacuum cleaner to pick up loosedirt and debris.

• Use low pressure air (not to exceed 25psi) to blow away dirt. Inspect cooling airslots and openings on the generator.These openings must be kept clean andunobstructed.

WARNINGStorage batteries give off explosivehydrogen gas during recharging.

Slightest spark will ignite hydrogenand cause explosion.

Battery electrolyte fluid contains acidand is extremely caustic.

Contact with battery contents willcause severe chemical burns.

A battery presents a risk of electricalshock and high short circuit current.

• DO NOT dispose of battery in fire.• DO NOT allow any open flame, spark,

heat, or lit cigarette during and for severalminutes after charging a battery.

• DO NOT open or mutilate the battery.• Wear protective goggles, rubber apron,

and rubber gloves.• Remove watches, rings, or other metal

objects.• Use tools with insulated handles.

CAUTIONInstalling the control panel’s 15A fusecould cause the engine to start.

• DO NOT install this fuse until all plumbingand wiring has been completed andinspected.

NOTICEImproper treatment of generator can damageit and shorten its life.

• DO NOT expose generator to excessivemoisture, dust, dirt, or corrosive vapors.

• DO NOT insert any objects through cool-ing slots.

17

2

SECTION 2 - TROUBLESHOOTING

SYSTEM CONTROL PANEL(SCP)

The System Control Panel (SCP) is a printedcircuit board that is integrated with the controlpanel of the Home Standby System. It containsall the logic circuits, operator controls, andsystem displays necessary to operate, program,and protect the generator. The system controlpanel interprets and monitors electrical inputsfrom related circuits throughout the standbyinstallation.Before replacing the system control panel, allother circuits must be tested to ensure properoperation. When a failure has been traced to thesystem control panel, the board must bereplaced as a complete assembly.Functions of the System Control Panel:

• Battery Trickle Charge• Set Exercise Timer (SET EXERCISE)• Manual Start (MANUAL OVER-RIDE)• Sensing Utility Voltage• Automatic Start, in event of utility failure• Automatic Engine Cool-Down Timer• Fault Code Detection with Automatic

Shutdown• Fault Indication Display (LED)• Diagnostic Access Port (SERVICE

TOOL)• Hour Meter

Power During SCP Fault Conditions

When the Home Generator System experiencesa fault condition, the automatic transfer switchautomatically defaults to UTILITY POWER.Thisensures that utility power is available to allcircuits in the home until the fault is corrected.

If the unit fails to exercise at its prescribed time,check for a fault code on the generator controlpanel display. If no fault code is shown, performthe SET EXERCISE procedure.

How to ACCESS the System Control Panel

The system control panel is mounted behind theface of the control panel (Figure 1,A).

1. Remove the control panel door.

Figure 1

2. Make sure the SYSTEM switch is set toOFF.

3. Remove the 15 AMP fuse from the systemcontrol panel.

4. Disconnect the negative (-) battery cable.5. Disconnect 10-pin connectors from the

edge of the system control panel board.6. Remove the four mounting screws (Figure

2, A) that secure the face of the controlpanel, then carefully remove and tilt downthe panel to expose the board.

Figure 2

The system control panel is connected to itsvarious circuits through three connectors that aremounted directly to the board (Figure 3), showntilted down.

18

2

The 8-pin connector (A) is wired to the internalsystems of the unit and is the primary point ofmeasurement for troubleshooting. The connectorsupplies 240VAC from UTILITY power. The 10-pin connector (B) is used for optional generatorfeatures. In addition, the system control panelalso has connections for L1 and L2 (C), whichsense 240VAC on the generator, and fourterminals (D), which are used for optimal batteryand engine warmers.

Figure 3

To show probe locations for troubleshooting witha test meter, an arrow from a connector/pinillustration will be shown against the exposedsystem control panel board (Figure 4). Note thatthe board will be shown upside down in relationto the actual schematic in the manual.

Figure 4

The functions of the 8-pin connector is shown in(Figure 5).

Figure 5

FAULT CODE INDICATIONSThe system control panel is equipped withsensing circuits that automatically shut down thegenerator in the event of potentially damagingconditions.

A digital display on the face of the control panelwill show the type of failure (FAULT CODE) thathas occurred. An optional LED indicator can bemounted elsewhere in the system to provide aremote indication of generator failures.

When the system control panel senses acondition that prevents the generator fromfunctioning properly, it shuts down the generatorand displays the fault code on the control panel.At the same time, it signals the remote LED toflash in a sequence that corresponds to the faultcode.8

7654321

12345678

Battery Trickle Charge (Wire #13)

Ground (Wire #0)

Start Circuit (Wire #56)

Fuel Solenoid (Wire #14)

Oil Temperature (Wire #95)Oil Pressure (Wire #85)

Vacant

Vacant

Pin

PinPinPin

PinPinPin

Pin

19

2

For example, “FC_1” (Fault Code) on the controlpanel display indicates Low Battery Voltage andthe remote LED would repeatedly flash once witha pause until it’s reset or the condition iscorrected. “FC_2” Low Oil Pressure would causethe remote LED to repeatedly flash twice andpause. Following is a list of the possible faultcodes.

(FC_1) Low Battery Voltage(FC_2) Low Oil Pressure(FC_3) Low Output Voltage(FC_4) Engine Fails To Start(FC_5) Low Frequency(FC_6) Engine Overspeed(FC_7) High Temperature(FC_8) Transfer Switch Failure

Resetting the Fault Code Detection System

After correcting the failure indicated by the faultcode, the operator or technician must reset thefault detection system before the Home StandbySystem will operate.

1. Place the SYSTEM switch in the OFFposition for 5 seconds or more.

2. Place the SYSTEM switch in the AUTOposition.

If the fault code is not corrected, the unit willreturn to Auto Shutdown and the same fault codeindication(s) will be displayed.

STOPPING THE SYSTEM FORMAINTENANCE

1. Ensure the main line disconnect (MLD) isON and power is supplied to the UTILITYCONNECTION lugs of the transferswitch.

2. Set the generator SYSTEM to OFF.3. Set the generator main circuit breaker to

OFF.4. Remove the 15 Amp fuse from the system

control panel.NOTE: Exercise timer will need to be resetwhenever the control panel fuse is removed.SEE RESETTING THE EXERCISE TIMER ONPAGE 13.

WARNINGTurn switch to OFF.Remove 15 Amp fuse from the systemcontrol panel.Disconnect spark plug wire from plug.

This will prevent accidental starts.

20

2

GENERATOR AC CONNECTIONSYSTEM

A single-phase, three-wire AC connection isused in the Home Generator System. The statorassembly consists of a pair of stationarywindings with two leads brought out of eachwinding. The junction of leads L2 & L3 forms theneutral lead, as shown schematically and aswiring diagram (Figure 6). A complete schematicand wiring diagram can be found later in thismanual.NOTE: Neutral is not bonded to ground atgenerator.

Figure 6

21

2

FC_1

DEAD UNIT/LOW BATTERYVOLTAGE

Figure 7

22

2

(FC_1)

DEAD UNIT/LOW BATTERYVOLTAGE

If the generator cannot start because the batteryoutput power is below that needed to crank theengine, the digital display will show FC_1 andthe remote LED will repeatedly flash once with apause.NOTE: A completely discharged battery will notbe capable of powering any of these displays.The causes for a low or discharged battery maybe:

• Blown Automatic Transfer SwitchFuse(s)

• Blown fuse(s) in circuit breaker panel• Blown system control panel fuse• Blown battery fuse• Blown ECU fuse• Failed system control panel trickle

charger• Failed battery• Parasitic drain on battery

The circuit functions and test/repair proceduresfor these conditions are outlined below.

SEE SCHEMATIC ON PAGE 60 FOR CIRCUITDETAILS.

NOTE: The trickle charge circuit is a floatcharger type. 240VAC UTILITY is delivered fromthe fuses in the transfer switch to the fuses in thegenerator circuit breaker panel. From there itflows to the 2 spade connectors mounted directlyon the system control panel board. The systemcontrol panel uses internal circuits to rectify thisUTILITY voltage to 12VDC. It is then delivered tothe (+) battery post through the 15 Amp fuse onthe system control panel via Pin #1, Wire #15A,20 Amp Engine Control Unit (ECU) fuse and the50 Amp battery fuse. When UTILITY voltage ispresent and the unit is switched to the AUTO orOFF position, the trickle charge circuit in thesystem control panel will maintain the voltage ofa fully charged battery. The trickle is not capableof charging a dead battery.

TEST 1 - Check Battery1. Set SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Disconnect battery cables, negative (-)

first.4. Using the approved procedure for your

battery tester, check the battery state-of-charge.

If the battery is discharged, connect to anappropriate battery charger. Charge the batteryin accordance to the battery manufacturerinstructions.If the battery replacement is required, thereplacement must be the same 12VDC, with anAmp rating specified in the unit installation oroperator manual.

5. Connect the battery cables, positive (+)first.

6. Reinstall the 15 Amp fuse in the systemcontrol panel.

7. Set SYSTEM switch to AUTO, then pushand hold MANUAL OVER-RIDE to startthe unit.

8. Reset the exercise timer.

TEST 2- Check Trickle Charge Voltage atBattery

NOTE: The trickle charge system will not operateif the battery voltage is below 10VDC. To test the

WARNINGBattery posts, terminals, and relatedaccessories contain lead and leadcomponents, chemicals known to the Stateof California to cause cancer andreproductive harm. Wash hands afterhandling.

WARNINGUtility voltage is present at the systemcontrol panel board.

Use caution to avoid personal electrical shockor damage to the system.

23

2

trickle charge output, a fully charged batterymust be installed in order to turn the tricklecharge on.

1. Set SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

contol panel.3. Inspect the fuse to see if blown.

• If fuse is good, proceed to Step 4.• A blown fuse indicates a short in the

circuit. Repair any short and replacefuse before proceeding to Step 4.

4. Disconnect the negative (-) battery cable.5. Disconnect the positive (+) battery cable

from the starter motor.6. Isolate Wire #13 (small wire) from the

positive (+) battery cable (Figure 8).Do notallow Wire #13 to touch ground.

Figure 8

7. Reconnect negative (-) battery cable tonegative battery terminal.

8. Ensure UTILITY voltage is turned ON.9. Reinstall 15 Amp control panel fuse.10. Set the meter to measure DC voltage.

Connect positive (+) meter test lead toWire #13. Connect negative (-) meter testlead to negative (-) battery terminal.

11. While observing the meter and keepingthe positive (+) meter test lead connectedto Wire #13, momentarily touch Wire #13and meter test lead to the positive (+)battery cable, then remove (Figure 9). Thiswill turn on the trickle charger long enoughto read the trickle charge output voltageon the meter.

Figure 9

12. About 13.5 VDC should be measuredwhen the wire is removed from the post.The trickle charge voltage will diminishquickly.

• If no voltage is measured, proceed toTEST 3 - Check 50 Amp BatteryFuse.

• If voltage is measured, the tricklecharger is functioning. Reconnect allwiring, return the unit to standby modeand reset the exercise timer.

24

2

Test 3 - Check 50 Amp Battery Fuse

1. Inspect the 50 Amp fuse in Wire #13located close to the starter motor(Figure 10,A).

Figure 10

• If the fuse is good, proceed to TEST 4 -Check Trickle Charge Voltage at Pin#1.

• A blown fuse indicates a short in thecircuit. Inspect the circuit and repairany shorts. Replace fuse.

TEST 4 - Check Trickle Charge Voltage at Pin#1.

1. Ensure UTILITY power is turned ON to thetransfer switch.

2. Set SYSTEM switch to OFF.3. Remove the 15 Amp fuse from the system

control panel.4. Make sure Wire #13 is reinstalled to the

positive (+) battery cable at the startermotor and the 50 Amp fuse is installed inWire #13.

5. Gain access to the control panel.SEE HOW TO ACCESS THE CONTROL PANEL ONPAGE 17.

6. Set meter to measure DC Voltage.Connect positive (+) meter test lead to Pin#1, Wire #13 (Figure 11).

Figure 11

7. Connect negative (-) meter test lead tonegative (-) battery terminal.

• If battery voltage is measured, proceedto Step 8.

• If no battery voltage is measured,proceed to TEST 8 - Check ECUFuse.

8. Reinstall the 15 Amp fuse in the systemcontrol panel. After a few seconds, metershould measure trickle charge voltagearound 13.5 VDC.

9. While observing the meter and keepingthe positive (+) meter test lead connectedto Pin #1, Wire #13, remove the 50 Ampbattery fuse in Wire #13, located near thestarter motor. The trickle charger will stayon long enough to read the trickle chargeoutput voltage on the meter, but tricklecharge voltage will diminish quickly.

• If 13.5 VDC is measured at Pin #1,Wire #13, but not at the positive (+)battery connection, proceed to TEST 5- Check 240 VAC Across Wire #92 &#93.

• If no voltage in measured at Pin #1,Wire #13, proceed to TEST 8 - CheckECU Fuse.

TEST 5 - Check 240 VAC Across Wire #92 andWire #93.

1. Remove the 15 Amp fuse from the systemcontrol panel.

2. Gain access to the system control panel.3. Verify Utility Voltage is ON.

SEE HOW TO ACCESS THE SYSTEM CONTROLPANEL ON PAGE 17 .

WARNINGUtility voltage is present at the systemcontol panel board.


25

2

4. Set meter to measure AC Voltage.Connect test leads across Wires #92 and#93. 240 VAC Utility should be measured(Figure 12).

Figure 12

• If no voltage is measured, proceed toTEST 6.

• If 240 VAC UTILITY is measured, verifyno trickle charge output is present asdescribed in TEST 4 - Check TrickleCharge Voltage at Pin #1. If no tricklecharge voltage is measured, but 240VAC Utility is present at Wires #92 and#93, replace the system control panel.

TEST 6 - Check for 240VAC at 10 Amp FuseInside Circuit Breaker Panel.

1. Make sure Utility power is turned OFF tohome generator system.

2. Set SYSTEM switch to OFF.3. Remove the 15 Amp system control panel

fuse.4. Remove the circuit breaker cover (Figure

13).

Figure 13

5. Check the two fuses located inside thecircuit breaker box (Figure 14, A).

Figure 14

• A blown fuse indicates a shorted circuit.Repair any shorts and replace fuse.

• If fuse is okay, continue with Step 6.

6. Ensure the Utility power is turned ON tothe system control panel.

7. Set meter to measure AC Voltage.8. Check for Utility voltage across the two

wires coming from Utility power. 240 VACUtility should be measured.

WARNINGUtility voltage is present at the systemcontol panel board.


26

2

• If 240 VAC Utility voltage is present atthe fuse connections, but not at thesytem control panel, repair any wiringbetween the fuses and the systemcontrol panel.

• If no voltage is present, proceed toTEST 7 - Check for 240 VAC at 10Amp fuse inside Automatic TransferSwitch.

TEST 7 - Check for 240 VAC at 10 Amp FuseInside Automatic Transfer Switch.

1. Gain access to the Automatic TransferSwitch.

2. Check the two fuses located inside theAutomatic Transfer Switch.


• If fuses are okay, proceed with Step 3.3. Make sure Utility voltage is turned ON.4. Measure for Utility voltage across wires on

the load side of the fuses, going to thestandby generator (Figure 15).

Figure 15

• If 240 VAC Utility is present at the fusesin the transfer switch, but no voltage ispresent at the fuses in the generator,there is an open circuit between thegenerator and the Automatic TransferSwitch. Repair/replace any defectivewiring and proceed to TEST 2 - CheckEngine Oil Pressure.

• If no voltage is present at the fuses inthe Automatic Transfer Switch, repair/

replace wiring between Utility powerand the fuse holder.

TEST 8 - Check ECU Fuse.1. Turn the SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Remove the system control panel cover to

gain access (Figure 16).

Figure 16

4. Locate and inspect the 20 Amp ECU fuse(Figure 17,A).

Figure 17

• A blown fuse indicates a short in thecircuit. Because this fuse primarilyprotects the ECU and it’s functions, ablown fuse would likely be related tosomething in the ECU or throttlecontrol. Repair or replace any shortsand replace the fuse, then proceed toTEST 2 - Check Engine Oil Pressure.

• If the fuse is good, proceed to Step 5.5. Set meter to measure DC Voltage.

27

2

6. Measure for 12 VDC at fuse on load side,Wire #15A (Figure 18).

Figure 18

• If voltage is present at the fuse but notpresent at Pin #1, Wire #15A on theCMA, repair/replace wiring betweenthe 50 Amp fuse and the ECU fuse.

• If no voltage is present, repair/replacewiring between 50 Amp battery fuse(Figure 10,A) and ECU fuse.

7. After repair, proceed to TEST 2 -CheckEngine Oil Pressure.

29

2

FC_2 LOW OIL PRESSURE

Figure 19

30

2

(FC_2)

LOW OIL PRESSURE

The standby generator is equipped with a LowOil Pressure (LOP) switch. The contacts of theswitch are normally closed, but are held open byengine oil pressure during operation. Should theengine oil pressure drop below a predeterminedlevel, the contact will close. This completes acircuit to ground Wire #85 and the systemcontrol panel shuts the engine down.

The digital display will show FC_2 and theremote LED will repeatedly flash twice with apause.During cranking and immediately after enginestart, the following occur:

• The system control panel bypasses theLOP switch for several seconds duringthe initial cranking.

• The LOP switch opens when engineproduces sufficient oil pressure.

• The system control panel senses thatthe engine is running by monitoringvoltage on Wires #L1 and #L2.

• After the system control panel sensesthat the engine is running, it looks for aground on Wire #85.

• If Wire #85 is grounded, the systemcontrol panel shuts the engine downand displays FC_2.

Refer to Figure 19 for troubleshooting flow.

Correcting Low Oil Pressure1. Fix any obvious oil leaks and, if

necessary, add the recommended oil tothe FULL mark on the dipstick.

2. Reset the fault code detection system.

SEE RESETTING THE FAULT CODE DETECTIONSYSTEM ON PAGE 19 .

3. Start the generator and listen for anyabnormal sounds that might indicateengine damage from low oil.

SEE TESTING MANUAL OPERATION (NO LOAD)ON PAGE 52.

• If a low oil pressure condition stillexists, the engine will shut down afterapproximately 10 seconds and thecontrol panel will again display FC_2.Proceed to TEST 1 - Measure forShort-To-Ground.

TEST 1 - Measure for Short-To-Ground1. Set the SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Turn off Utility voltage to the standby

generator.4. Remove the control panel cover to gain

access to the system control panel.SEE HOW TO ACCESS THE SCP ON PAGE 17.

5. Remove the the 8-pin connector from thesystem control panel (Fig. 20).

Figure 20

6. Measure for short-to-ground on Wire #85(Figure 21).


31

2Figure 21

• If no short is detected, proceed toTEST 2 - Check Engine Oil Pressure.

• If short is detected, continue with Steps7 - 12.

7. Repair and/or replace wiring, asnecessary, then retest.

8. Reconnect Wire #85 to the LOP switch.9. Reconnect the 8-pin connector to the

system control panel.10. Reinstall the control panel cover.11. Reinstall the 15 Amp fuse in the system

control panel.12. Set the SYSTEM to AUTO, then push

and hold MANUAL OVER-RIDE to startthe unit.

TEST 2 - Check Engine Oil PressureContact Power Solutions, Inc (PSI TechnicalService Specialists: 1-888-331-5764 or at:[email protected]) forspecifications, testing, and troubleshootingengine oil pressure.

• If oil pressure is normal, proceed toTEST 3 - Check Oil Pressure Switch.

• If oil pressure is low, contact enginemanufacturer for enginetroubleshooting procedure.

TEST 3 - Check Oil Pressure Switch1. If it is not already, install the LOP switch.2. Turn the SYSTEM switch to AUTO. Push

and hold the MANUAL OVER-RIDEswitch to start the engine.

3. With the engine running, check the switchwith a continuity tester The switchcontacts should be open (no continuity).

• If the switch is OK, replace the systemcontrol panel, and proceed to Step 4.

• If the switch is defective, replace it andcontinue with Steps 4-9.

4. Reset the fault code detection system.SEE RESETTING THE FAULT CODE SYSTEM ONPAGE 19.

5. Start the generator and verify FC_2 doesnot occur.

6. Set SYSTEM switch to OFF.7. Turn UTILITY ON (if turned off).8. Return SYSTEM switch to AUTO.9. Reset the Exercise Timer.

SEE SETTING THE EXERCISE TIMER ONPAGE 13.

33

2

Figure 22

34

2

(FC_3)

LOW OUTPUT VOLTAGE

The low voltage shutdown feature is designed toprotect the generator and its loads from anoutput voltage that is too low. When thegenerator has stabalized, the system controlpanel senses output voltage on Pins #J8 and#J9 and on Wires #L1 and #L2.SEE WIRING DIAGRAM ON PAGE 61.If the system contol panel does not sense theproper generator voltage, it will shut down theunit.The digital display will show FC_3 and theremote LED will repeatedly flash three times witha pause.Low output voltage may be caused by:

• An open control panel circuit breaker• A generator that is overloaded• A restriction in the fuel flow• A broken or disconnected signal lead

(L1 or L2)• Diminished engine power• A failed alternator winding• Open wiring

TEST 1 - Measure Circuit Breaker Load-SideVoltage

1. Remove the cover from the generatorcircuit breaker.

SEE TESTING MANUAL OPERATION (NO LOAD)ON PAGE 52.

2. Reset the fault code detection system.SEE RESETTING THE FAULT CODE DETECTIONSYSTEM 19.

3. Ensure that the generator circuit breaker isON and the 15 Amp control panel fuse isinstalled .

4. Turn the SYSTEM switch to AUTO, thenpush and hold the MANUAL OVER-RIDEbutton to start the generator.

5. When the unit has stabalized, check for240VAC at the load side of the circuitbreaker (Figure 23).

Figure 23

• If the specified voltage is present,proceed to TEST 2 - MeasureGenerator Voltage at SystemControl Panel.

• If specified voltage is not present,proceed to TEST 3 - Measure CircuitBreaker Line-Side Voltage.

TEST 2 - Measure Generator Voltage atSystem Control Panel

1. Remove control panel cover to gainaccess to the system control panel.

SEE HOW TO ACCESS THE SYSTEM CONTROLPANEL ON PAGE 17.

2. With the unit running, measure for240VAC at system control panelPins J8 and J9 and Wires # L1 and L2(Figure 24).




35

2Figure 24

• If no voltage is present:A. Ensure the circut breaker is

ON.B. Repair or replace the wiresbetween the circuit breaker andL1 and L2.

C. Restest for 240VAC.• If 240VAC is present, replace the

system control panel board.

TEST 3 - Measure Circuit Breaker Line-SideVoltage

1. Ensure the circuit breaker is ON.2. Start the generator and measure for

240VAC on the line-side of circuit breaker.

• If there is no voltage on the line-side ofthe breaker, proceed to TEST 4 -Bypass the Automatic VoltageRegulator.

• If there is voltage on the line-side of thebreaker, but none on the load-side,manually cycle the circuit breaker andretest. If there is still no voltage on theload-side, replace the circuit breaker.

NOTE: For complete alternator technical supportcontact Marathon Electric Generators at:100 E. Randolf Street, PO Box 8003,Wausau,Wisconsin, 54401-8803, or at 715-675-3311, orat www.marathonelectric.com.

TEST 4 - Bypass the Automatic VoltageRegulator (AVR)NOTE: The generator “No Load” voltage isdependent on exciter input voltage andgenerator speed. With the generator operating atrated speed and 12 VDC applied to the exciterfield, the generator’s terminal voltage will be nearrated value.

1. Set SYSTEM swith to OFF.

2. Remove the 15 Amp system control panelfuse.

3. Gain access to the Automatic VoltageRegulator (AVR). Position control panelassembly and secure secure with tiestraps as needed. (Figure 25).

Figure 25

4. Disconnect the positive (F+) and negative(F-) AVR leads and while observingcorrect polarity, connect them to a 12Vbattery.

5. Reinstall the 15 Amp control panel fuse.6. Turn the SYSTEM switch to AUTO, then

push and hold the MANUAL OVER-RIDEbutton to start the generator.

7. Measure the terminal voltage, andcompare with rated voltage (Figure 26).

Figure 26

• If the specified voltage is present,replace the automatic voltageregulator.

• If the specified voltage is not present,proceed to TEST 5 - Test AlternatorWindings.

36

2

TEST 5 - Test Alternator WindingsThere are four components that contain windingsthat form an electrical path of low resistance.Each component can be checked for continuity.To Check Winding for Continuity:

1. Using meter, measure the loop resistanceof the following four components:• Exciter Stator• Exciter Rotor• Main Stator• Main Rotor

2. Verify measured values against thoselisted in the table below.

NOTE: These very small resistances requireprecision test equipment to obtain accuratemeasurements. However, a standard meter willprovide a good indication of winding continuity.

Figure 27 Generator Stator Resistance

Figure 28 Generator Rotor Resistance

Figure 29 Exciter Stator Resistance

Figure 30 Exciter Rotor Resistance

• If winding resistance isacceptable,proceed to InsulationResistance Test.

• If winding resistance is not acceptable,repair or replace as necessary.

Generator Resistance Exciter ResistanceStator Rotor

ExciterField No

Load Volts Stator Rotor0.07 0.46 10.1 18.0 0.120

37

2

Insulation Resistance TestThis test measures the quality of the insulationmaterials that keep the electrical windings andthe generator’s steel core seperated.Dust, dirt, and moisture can cause the insulationto erode over time. Most winding failures are dueto a failure in the insulation system.Winding insulation can be checked on the mainstator and rotor and on the exciter stator androtor.

1. Set SYSTEM switch to OFF.2. Remove the 15 Amp system control panel

fuse and disconnect the negative (-)battery cable.

3. Remove all regulators, diodes, surgeprotectors, capacitors and relays from thewinding circuit before testing.

4. Using a mega-ohm meter, check for aminimum insulation resistance of 2 mega-ohms.

• If insulation resistance is acceptable,proceed to Diode Test.

• If insulation resistance is notacceptable, repair or replace asnecessary.

Diode TestNOTE: To access diodes, the engine must berolled over. Contact engine manufacturer forinstructions on how to roll over engine.

1. Remove the 2 main rotor leads from therectifier assembly.

2. Remove the 3 exciter rotor leads fro therectifier assembly.

• The diodes and the diode test leads willremain mounted to the posts during thetesting process.

3. Using meter set to measure Ohms (Ω),place one test lead on the diode leadterminal post.

4. At the same time, touch the other test leadto the diode mounting nut (Figure 31).

Figure 31

5. Reverse the test lead probes and repeatSteps 3 and 4 (Figure 32).

Figure 32

6. Using Steps 3-5, test the six diodes in theforward and the reverse directions.

• If the diode is GOOD, greaterresistance will be measured in onedirection more than the other.

• If the diode is SHORTED, the meter willread “0” or, the resistance will be verylow in both directions. Replace therectifier assembly if one or more diodesare SHORTED.

• If the diode is OPEN, the meter willhave an infinity reading in bothdirections. Replace the rectifierassembly if one or more diodes areOPEN.

39

2

Figure 33

40

2

(FC_4)

ENGINE FAILS TO START

Whenever the unit is directed to start (MANUALOVER-RIDE or AUTO), the system control paneldelivers 12VDC from Wire #56, Pin #3 to thestarter contactor for 10-15 seconds. It thenpauses for 10-15 seconds and repeats theattempt until 2 minutes of start time haveaccumulated.During the strarting attempt, the starter controlpanel also delivers 12VDC from Pin #4, Wire#14 to the 5 Amp fuse. From the fuse, Wire#14A delivers the 12 VDC to both the fuelsolenoid and the ECU (Engine Control Unit).From the fuel solenoid, Wire #14B delivers thisvoltage to Pin #5 on the ECU. The ECU controlsthe opening of the fuel valve, controlling fuelflow. Wire #14A also delivers 12 VDC to Pin #15on the ECU. This is considered a “key on” signal.Pins #22 and #23 on the ECU recieve a signalfrom the RPM sensor. This signals the ECU thatthe engine is rotating. When these signals arereceived, the ECU will ground Wire #56A (Pin#3 on the ECU). This will energize PR (PowerRelay) closing it’s contacts. When the PR isenergized, 12 VDC on Wire #15B is connectedto the ignition coil and engine alternator. Thesystem control panel also monitors Wires #L1and #L2 for a minimum voltage. When thesystem control panel receives the minimumvoltage signal, it recognizes the generator hasstarted and discontinues the voltage signal to thestarter contactor. However, if the minimumvoltage has not been sensed after approximately2 minutes of accumlative start time, the systemcontrol panel terminates the engine crankingcycle.The digital display will show FC_4 and theremote LED will repeatedly flash four times witha pause. The engine will not start until the FC_4is cleared.

This fail code directs the service technician toexamine systems that could be preventing theunit from operating. For example:

• No Alternator Output Voltage• Circuit Breaker in OFF position• No Fuel• Blown Fuse• Fuel Solenoid Failure• Fuel Supply Discrepancies• Failed Starter Motor• Failed Starter Motor Connections• Engine Component Failures• Clogged Engine Air Filter• Failed Ignition System• Failed Battery Fuse• Failed ECU Fuse• Failed Fuel Solenoid Fuse• Failed ECU• Failed and/or Damaged Wiring• Clogged Atmospheric Vent

Troubleshooting Engine Start Failures1. Reset the fault code detection system.

SEE RESETTING THE FAULT CODE DETECTIONSYSTEM ON PAGE 19.

2. Set SYSTEM switch to AUTO and pushMANUAL OVER-RIDE to start the unit.

3. The engine will do one of the following:• The engine will start and stop several

times through the 2 minute cycle. If theengine starts and shuts down every 10-15 seconds for a two minute durationthen finally shuts down, and FC_4 isshown on the digital display, the failureis caused by no voltage on Wires L1 &L2 at the system control panel. AnOPEN MAIN CIRCUIT breaker couldbe the cause. Use FC_3troubleshooting for this condition(Page 34).

• The engine will crank and fail to start.Use TESTS 1-5 for starting failures.

• The engine will fail to crank. UseTESTS 1-4 for cranking failures.


41

2

ENGINE FAILED TO START

TEST 1 - Check Fuel Solenoid Signal1. Turn SYSTEM switch to OFF.2. Remove the 15 fuse from the system

control panel.3. Disconnect Wire #14A from the fuel

solenoid.4. Set meter to measure DC Voltage.

Connect positive (+) meter test lead towire (Figure 34,A).

Figure 34

5. Connect negative (-) meter test lead tobattery negative post (Figure 27,B).


7. Turn SYSTEM switch to AUTO.8. While observing the meter reading, push

and hold the MANUAL OVER-RIDEbutton. Battery voltage should bemeasured.

• If battery voltage is measured, proceedto TEST 3 - Check Ignition CoilSignal.

• If no voltage is measured, proceed toTEST 2 - Check SCP Output.

TEST 2 - Check SCP Output

1. Turn SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Gain access to system control panel.

SEE HOW TO GAIN ACCESS TO SYSTEMCONTROL PANEL ON PAGE 17.

4. Set meter to measure DC Voltage.Connect positive (+) test lead to Pin #4,Wire #14 (Figure 35).

Figure 35

5. Connect negative (-) meter test lead tobattery ground.


7. Turn the SYSTEM switch to AUTO.8. While observing the meter reading, push

and hold the MANUAL OVER-RIDEbutton. Battery Voltage should bemeasured.


• If no voltage is measured and enginecranks but does not start, replace thesystem control panel.



42

2

9. Turn the SYSTEM switch to OFF.10. Remove the 15 Amp fuse from the

system control panel.11. Inspect the 5 Amp fuse located in Wire

#14 (Figure 36,A).

Figure 36


• If fuse is okay, proceed to Step 13.12. Connect the positive (+) meter test lead

to the load side of the 5 Amp fuse, next toWire #14A. Connect negative (-) test leadto the negative (-) battery terminal (Figure27).


14. Turn SYSTEM switch to AUTO.15. While observing the meter, push and

hold the MANUAL OVER-RIDE button.Battery voltage should be measured .

• If battery voltage is measured at theload side of the fuse, repair/replacewiring between 5 Amp fuse and fuelsolenoid, Wire #14A.

• If no voltage is measured, repair/replace wiring between 5 Amp fuseand system control panel.

TEST 3 - Check Ignition Coil Signal1. Turn the SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Unplug the Wire #18 (purple wire)

connector from the ignition coil (Figure37).

Figure 37

4. Set meter to read DC Voltage.5. Insert the positive (+) meter test lead to

Wire #18.6. Insert the negative (-) meter test lead to

the battery negative terminal.7. Reinstall the 15 Amp fuse in the system

control panel.8. While obseving the meter, push and hold

the MANUAL OVER-RIDE button. Batteryvoltage should be measured.

• If battery voltage is measured, the CMAand the ECU control logic arefunctioning normally. Proceed to TEST4 - Check Fuel Supply Pressure.

• If no battery voltage is measured,proceed to TEST 5 - Check ECUInputs.

43

2

TEST 4 - Check Fuel Supply Pressure1. Install Briggs & Stratton manometer

#19495 as illustrated in (Figure 38) toverify that fuel pressure is available to thefuel solenoid. LP or NG fuel supplypressure should be 7 to 11 inches ofwater (in W.C.) at full load with all gasappliances turned on and operating.

Figure 38

• If the proper fuel pressure is notpresent, repair and/or replace the fueldelivery system, then re-test the fuelpressure as described above.

• If fuel pressure is acceptable, go toTEST 5 - Check ECU Inputs.

TEST 5 - Check ECU InputsThe ECU needs to receive several inputs beforean engine start will occur. It must receive:

• A connection to battery negative (-)terminal through Pin #10, Wire #0.

• Battery voltage during engine crank atPin #15, Wire #14A.

• Battery voltage during engine crank atPin #5, Wire #14B.

• Battery voltage at Pin #11, Wire #15A.• Battery voltage at Pin #3, Wire #56A.• A frequency signal at Pins #22 and #23

from the engine RPM sensor.When all of these conditions are present theECU will connect Wire #56A and #14B toground. This closes the Power Relay to supplybattery voltage to the ignition and enginealternator, and opens the fuel solenoid.

To Test ECU Inputs:1. Turn the SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Gain access to the system control panel.

SEE HOW TO ACCESS SYSTEM CONTOL PANELON PAGE 17.

4. Disconnect the wiring harness from theECU.

5. Set the meter to measure continuity. Insertone test lead in Pin #10, Wire #0 and theother test lead to the negative (-) batteryterminal. Continuity should be measured(Figure 39).

NOTE: When inserting a test lead into the ECUconnector, use caution to not damage terminals.

Figure 39

• If continuity is measured, proceed toStep 6.

• If no continuity is measured, repair/replace wiring between Pin #10, Wire#0and the negative (-) battery terminal.

6. Set the meter to measure DC Voltage.Connect the positive (+) meter test lead toPin #15, Wire #14A, and connect thenegative (-) meter test lead to batteryground (Figure 40).

Figure 40

10

15

44

2


8. Turn SYSTEM switch to AUTO.9. While observing the meter, push and hold

the MANUAL OVER-RIDE button. Batteryvoltage should be measured. TurnSYSTEM switch to OFF.


• If no voltage is measured, repair/replace wiring between Pin #4, Wire#14 on the CMA and Pin #15 ,Wire#14A on the ECU.

10. Insert positive (+) meter test lead to Pin#5, Wire #14B and the negative (-) metertest lead to negative (-) battery terminal(Figure 41).

Figure 41

11. Turn SYSTEM switch to AUTO.12. While observing the meter, push and

hold the MANUAL OVER-RIDE button.Battery voltage should be measured.Turn SYSTEM switch to OFF.


• If no voltage is measured, repair/replace wiring between Pin #4, Wire#14A on the CMA and Pin #5 , Wire#14B on the ECU.

13. Insert positive (+) meter test lead to Pin#11, Wire #15A and negative (-) metertest lead to battery negative (-) terminal.Battery voltage should be measured(Figure 42).

Figure 42


• If no voltage is measured, repair/replace fuses and/or wiring betweenthe positive (+) battery terminal andPin #11, Wire #15A on the ECU.

14. Insert positive (+) meter test lead toPin#3, Wire #56A and negative (-) meter testlead to battery (-) negative terminal.Battery voltage should be measured(Figure 43).

Figure 43


• If no voltage is measured, repair/replace fuses, wiring and/or powerrelay between positive(+) batteryterminal and Pin #3,Wire #56A on theECU.

15. Set meter to measure Ohms (Ω).16. Insert one test lead into Pin #22 and the

other meter test lead into Pin #23 (Figure44).

5

11

3

45

2Figure 44

17. Approximately 285 - 295 Ohms should bemeasured.

• If resistance is outside of this range,check for open/shorted wiring or RPMsensor.

• If resistance is within specifications,make sure RPM sensor is adjustedcorrectly as described below. If RPMsensor is adjusted correctly and theengine still does not start, contactPower Solutions Inc.(PSI TechnicalService Specialists, 1-888-331-5764 orat: [email protected])for further engine troubleshooting.

To Adjust RPM Sensor:1. Remove the RPM sensor (Figure 45,A).

Figure 45

2. Position a flywheel tooth in the center ofthe RPM sensor mounting hole.

3. Install RPM sensor and tighten untilsensor lightly touches the flywheel tooth.

4. Unscrew RPM sensor one completerotation.

5. While holding sensor in position, tightenlock nut.

23 22

46

2

Figure 46

47

2

CRANKING FAILURES

TEST 1 - Check Battery Components1. Check the condition and electrical

integrity of all wires, connectors, andcables throughout the home standby unit.Some areas of particular focus are:• Battery state of charge and

connections• Generator grounds, wiring, and

connectionsRepair any discrepancies and proceed to Step 2.

2. Attempt a MANUAL OVER-RIDE start andobserve system.

• If generator starts repair is complete.Reset exercise timer and returngenerator to AUTO.

• If generator fails to start, proceed toStep 3.

3. Remove and inspect the 15 Amp ControlPanel fuse.


• If fuse is okay, proceed to Step 4.4. Inspect the 50 Amp fuse in Wire #13

located close to the starter motor (Figure47,A).

Figure 47

• If the fuse is good, proceed to TEST 2 -Check Starter Contactor Signal.

• A blown fuse indicates a short in thecircuit. Inspect the circuit and repairany shorts. Replace fuse.

TEST 2 - Check Starter Contactor Signal1. Set meter to measure DC Voltage.

Connect positive (+) test lead to Wire #56at the starter contactor (Figure 48).

Figure 48

2. Connect negative (-) test lead to batteryground terminal.

3. Make sure SYSTEM switch is in AUTO.While observing the meter, push and holdthe MANUAL OVER-RIDE start button.Battery voltage should be measured.

• If no voltage is measured on WIRE #56at the starter contactor, proceed toTEST 3 - Check System ControlPanel Output.

• If battery voltage is measured at thestarter contactor but the starter motordoes not engage, verify engine groundconnections are good. Once allconnections are good, contact PowerSolutions, Inc. (PSI Technical ServiceSpecialists, 1-888-331-5764 or at:[email protected]) forfurther troubleshooting on the starterand engine.

TEST 3 - Check System Control Panel Output1. Turn the SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Gain access to the system control panel.

SEE HOW TO ACCESS SYSTEM CONTROL PANELON PAGE 17.

4. Insert the positive (+) test lead to Wire#56,Pin #3 (Figure 49) and the negative(-) test lead to the battery ground terminal.

48

2

Figure 49


6. Put the SYSTEM switch in AUTO.7. While observing the meter, push and hold

MANUAL OVER-RIDE start button.Battery voltage should be measured.

• If battery voltage is measured at Wire#56,Pin #3, but is not measured at thestarter contactor as described in TEST2, Step 3, repair/replace wiringbetween the system control panel andstarter contactor.

• If no voltage is measured, proceed toTEST 4 - Check System ControlPanel Inputs.

TEST 4 - Check SCP Input1. Turn SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Set the meter to measure DC Voltage.4. Connect the positive (+) meter test lead to

Pin #1, Wire # 15A and the negative (-)meter test lead to battery ground terminal.(Figure 50). Battery voltage should bemeasured.

Figure 50

• If battery voltage is measured at Wire#15A, Pin #1 but was not measuredduring the test at TEST 3, Step 4-7,verify system control panel ground atWire #0, Pin #2. If ground is present,replace the system control panel.

• If no voltage is measured, proceed toStep 4.

5. Turn the SYSTEM switch to OFF.6. Remove the 15 Amp fuse from the system

control panel.7. Remove the system control panel cover to

gain access (Figure 51).

Figure 51

8. Locate and inspect the 20 Amp ECU fuse(Figure 52,A).

49

2Figure 52

• A blown fuse indicates a short in thecircuit. Because this fuse is designedto protect the ECU and its functions, ablown fuse would likely be related tosomething in the ECU or throttlecontrol. For troubleshootinginformation, contact Power Solutions,Inc. (PSI Technical Service Specialists,1-888-3311-5764 or at:[email protected])Repair or replace any shorts andreplace the fuse, then proceed to TEST2 - Check Starter Contactor Signal.

• If the fuse is good, proceed to Step 9.9. Set meter to measure DC Voltage.10. Measure for battery voltage at the ECU

fuse line side, Wire #15.• If voltage is present at the fuse but not

present at Wire #15A, Pin #1 on thesystem control panel, repair/replacewiring between the fuse and systemcontrol panel.

• If no voltage is present, repair/replacewiring between the 50 Amp fuse andthe ECU fuse.

11. When wiring repair is complete, retest toverify repair.

12. Reset exercise timer and returngenerator to AUTO.

51

2

Figure 53

52

2

(FC_5)

UNDER FREQUENCYThe troubleshooting steps for under-and over-frequency faults are identical. Refer to Fig. 29 totroubleshoot (FC_5) & (FC_6) fault indications.The low frequency shutdown feature is designedto protect the generator and its loads from anoutput frequency that is too low. The systemcontrol panel senses frequency at Wire # L1 andWire #L2. If output frequency drops below 55 Hzfor three seconds, the system control panel willshut down the generator.The digital display will show FC-5 and the remoteLED will repeatedly flash five times with a pause.Under frequency may be caused by:

• A restricted air filter• A failure in the generator sense wiring

(L1 or L2)• A failed engine governor• Problems with the fuel delivery system• Excessive loads• A failure at the system control panel• An engine that is not producing

sufficient power

TEST 1 - Check No-Load & Full-LoadFrequency

For the following procedures, we recommend theuse of Briggs & Stratton Tach and Hour meter(#19389) and Briggs & Stratton Frequency Meter(#19543) with Frequency Adapter (#19580).

Perform the following tests under full electricalloads with all gaseous fuel appliances turned ONand operating.

• No-Load RPM specification is 3750 +/-100 RPM / 62.0-62.5Hz

• Full-Load RPM specification is 3420 +/-100 RPM / 57.0-62.5 Hz

Check No-Load Frequency1. Turn the SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Remove the circuit breaker cover.4. Make sure the generator circuit breaker is

ON.5. Reinstall the 15 Amp fuse in the system

control panel.6. Set SYSTEM switch to AUTO, then push

and hold MANUAL OVER-RIDE to startthe unit.

7. Measure frequency at the load side of thecircuit breaker (Figure 54).


CAUTIONFollow the manufacturer’s instructions for thetype of frequency meter that you are using.

53

2

Figure 54

Check Full-Load Frequency1. Turn off Utility power to the transfer

switch. The generator should start andthe transfer switch should transfer. Slowlyadd electrical loads to the generator unituntil it is running at full capacity.

2. Measure the frequency at the load side ofthe circuit breaker.

If the frequency is correct, restore utility powerthen proceed to TEST 2 - Measure FrequencyL1 & L2.• If the frequency is not correct:

1. Verify fuels pressure and volume arewithin specifications.

2. Verify the air filter is not clogged.• If the engine speed is still too low, contactPower Solutions, Inc. (PSI Technical ServiceSpecialists, 1-888-3311-5764 or at:[email protected]) for governortroubleshooting information.

NOTE: If a full-load adjustment was required,recheck the frequency at no-load.

TEST 2 - Measure Frequency at L1 & L21. Gain access to the system control panel.

SEE HOW TO ACCESS SYSTEM CONTROL PANELON PAGE 17.

2. Inspect position of jumper on JP1 (Figure55,A). Jumper position must be located asshown for 60Hz application.

Figure 55

3. With the unit running, measure thefrequency at L1 and L2 at the systemcontrol panel pins (Fig 56).

Figure 56

• If the frequency is not correct, replace/repair the wiring between the circuitbreaker and L1 & L2 at the systemcontrol panel. Then re-test thefrequency at L1 & L2.

• If the frequency is correct but thegenerator continues to shut down forlow frequency, replace the systemcontrol panel board.

4. Reset the exercise timer.SEE RESETTING THE EXERCISE TIMER ONPAGE 13.

54

2

(FC_6)

OVER FREQUENCYThe troubleshooting steps for under and overfrequency faults are identical. Refer to (Figure30) to troubleshoot (FC_5) & (FC_6) faultindications.

NOTE: Over-frequency is a symptom of agovernor related issue. Contact Power SolutionsInc. (PSI Technical Service Specialists, 1-888-331-5764 or at:[email protected]) fortroubleshooting on the electronic governor.The CMA/Control Panel monitors generatoroutput frequency at Wire # L1 & L2. If thegenerator output frequency increases to 65Hz-70Hz, the system control panel waits threeseconds before shutting the unit down. Shouldthe frequency exceed 70Hz, the system controlpanel will shut down the generator immediatelyafter starting.

The reason for the 5Hz latitude in frequencysensing is that the engine governor will huntsomewhat before it finds the desired setting. Thiscauses variable frequency outputs that are notharmful until they reach the 65Hz - 70Hz range.

If the system control panel senses an over-frequency condition, the digital display will showFC_6 and the remote LED will repeatedly flashsix times with a pause.


55

2

Figure 57

56

2

(FC_7)

HIGH TEMPERATUREThe contacts of the Over Temperature Switch(OTS) are normally open. If the engine coolantreaches a critical temperature, the switchcontacts will close and complete a circuit toground through Wire # 95.

If the system control panel senses this ground, itwill shut down the generator. The digital displaywill show FC_7 and the remote LED willrepeatedly flash seven times with a pause.

Common causes for high temperature include:• Running the unit with the side doors

removed• Obstructed air inlet or exhaust port• Debris in the radiator cooling fins• Loose fan belt• Low coolant level

Contact Power Solutions, Inc. (PSI TechnicalService Specialists, 1-888-3311-5764 or at:[email protected]) for overheatingcaused by an engine component, such as aleaking gasket, water pump, or a faultythermostat.

Inspect for and correct any of these conditionsbefore checking the OTS. Once the problem iscorrected, reset the fault code detection system.SEE RESETTING FAULT CODE DETECTIONSYSTEM ON PAGE 19.

TEST 1 - Check Over-Temperature Switch1. Turn SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Remove Wire #95 (A) from the OTS.

Make sure the wire does not touch theground.

4. With the engine at room temperature testfor continuity of the switch (Figure 58).

Figure 58

• If no continuity is measured, the switchis good. Proceed to TEST 2 - CheckWire #95.

• If continuity is found, replace the OTS.5. Reconnect the wiring, install fuse and

reset the exercise timer.SEE RESETTING THE EXERCISE TIMER ONPAGE 13.

TEST 2 - Check Wire # 951. Turn SYSTEM switch to OFF.2. Remove the 15 Amp fuse from the system

control panel.3. Gain access to the generator control

panel.SEE HOW TO ACCESS THE SYSTEM CONTROLPANEL ON PAGE 17.

4. Remove the 8-pin connector from thesystem control panel board (Figure 59).


57

2Figure 59

5. Remove wire and measure for short-to-ground between Wire #95 and ground(Figure 60).

Figure 60

• If a short-to-ground is measured, repairand/or replace the wiring as necessary.

• If no short-to-ground is measured,replace the system control panel.

6. Reset the exercise timer.SEE RESETTING THE EXERCISE TIMER ONPAGE 13.

58

2

(FC_8)

TRANSFER SWITCH FAILUREA transfer switch with a compatible AirConditioning Control Module (ACCM III or laterversion) is required for this feature to function.This module monitors the transfer switch duringnormal utility power and during standby power.Not all transfer switches will have this feature.A transfer switch failure indicates an open circuitwithin the switch, which can occur:

• at the fuse(s)• in the contactor coils• in the limit switches• at the utility fuse(s) in the transfer

switch or generator• utility sensing wiring not connected to

generator

Because of wiring and connections, an opencircuit can occur in variable places, generatorsymptoms may vary. A visual inspection isgenerally sufficient to determine the source.Further troubleshooting can be done with acontinuity tester and a wiring diagram specific tothe model of transfer switch installed.NOTE: Most common cause of transfer switchfailures is a blown transfer switch fuse.

When a transfer switch failure occurs, the digitaldisplay will show FC_8 and the remote LED willrepeatedly flash eight times with a pause.The FC_8 fail code will not display if a failureoccurs while the unit is running in EXERCISE,MANUAL, or UTILITY mode.

• The fail code will display if a failureoccurs while the unit is stopped and setin AUTO mode.

• The unit will not shut down if a failureoccurs while the unit is deliveringstandby power. But the fail code willdisplay when power transfers back tothe utility.


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SECTION 3- SPECIFICATIONS &REFERENCE

GENERATOR SPECIFICATIONS

MODEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .076000NG & 076000LPRATED MAXIMUM POWER AND LOAD CURRENT (LPG) . . . . . . . . . . . . . . . . . . . . .30KW

AT 240 VOLTS 125 AMPSAT 120 VOLTS 250 AMPS

RATED MAXIMUM POWER AND LOAD CURRENT (NG) . . . . . . . . . . . . . . . . . . . . . .27KWAT 240 VOLTS 112.5 AMPSAT 120 VOLTS 225 AMPS

RATED AC VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120/240 VOLTSRATED FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 HZPHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SINGLE PHASERATED TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77°F (25°C)NG FUEL SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 IN. W.C.LPG FUEL SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 IN. W.C.NORMAL OPERATING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -20°F TO 104°F (-28.8°C TO 40°C)

RESISTANCE VALUES

GENERATOR STATOR RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.07GENERATOR ROTOR RESISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.46EXCITER STATOR RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18.0EXCITER ROTOR RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.120

FASTENER TORQUE VALUES

ISOLATOR MOUNTING 1/2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 LB-FTISOLATOR MOUNTING 3/8” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 LB-FTEXHAUST BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 LB-FTFLEX PLATE TO FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 LB-FTALTERNATOR HOUSING TO ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 LB-FT

TRANSFER SWITCH COMMUNICATION

REMOTE LED OUTPUT

+12VDC, 0.5A OUTPUT

+ _12V

BATTERY

RED

BLACK

BLACK

SMC

SMCENGINE

16 0SM

013

56BATTERY FUSE

50A15

15

ECU FUSE20 AMP

O(+)

A

B

ALT

15

15

COIL

A

BCAPPURPLE

GRAY

DELPHI

DELPHI

12182183

148121

POWER FUSE

15 AMP15B

PR15A (3) (5)

15A

15A

15A

7PR

856A

ECU3

11

22

23

10TWISTED PAIR

M/P 1/4” SPADE

THROTTLE

1

2

12

16

19

20

21

3

5

1

2

6

4PLUG

TYCO284716-A

COMMUNICATION PORT

DELPHI 12010973

A

B

TWISTED PAIR

15

5

14A

14A 14BFSV

FSV FUSE

5 AMP

0

95

85

WTS

230 FOPS

8-10 PSI

GND

GND

F-

F+

EXCITERCOIL

6/VAR7/VARF-F+

3

450HZ60HZ

FUSE

SEREGULATOR

L1NL2

GND

FRAME

L2L1

C.B.

GROUNDLINE 1LINE 2NEUTRAL

E1E2

CUSTOMER LOAD

GENERATOR240VAC

WARMER

OILPRESSURE

WATERTEMP

GND

FUELSOLENOID

+12VDC

15 AMP

STARTERMOTOR

GEN. CONTROL

N.O.COMN.C.

TxRx

TxRx GND.

+LED

GND

GND

+12 VDC

UTILITY POWERFROM

TRANSFER SWITCH

FUSE10 AMP

WATER JACKET220V 4.1A1OOOW

ALT - ALTERNATORC.B. - CIRCUIT BREAKERCOM - COMMONECU - ENGINE CONTROLFSV - FUEL SOLENOID VALVEGND - GROUNDMP - MAGNETO PICK-UPN.C. - NORMALLY CLOSEDN.O. - NORMALLY OPENOPS - OIL PRESSURE SWITCHPR - POWER RELAYSM - STARTER MOTORSMC - STARTER MOTOR CONTACTORTxRx - TRANSMIT/RECEIVEWTS - WATER TEMPERATURE SWITCH

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