Briggs & Stratton 076000-0 User manual

Home Generator System

Manual 278382GS Rev A 6/08

BRIGGS & STRATTON

SERVICE & TROUBLESHOOTING MANUAL

HOME GENERATOR SYSTEM - 30kW

FORWARD

This manual was written to assist authorized technicians and service personnel with the repair and

maintenance procedures for Briggs & Stratton home standby generator systems. It assumes that persons

using this manual have been properly trained in and are familiar with the servicing procedures for these

products, including the proper use of required tools and safety equipment and the application of

appropriate safety practices. Persons untrained or unfamiliar with these procedures or products should not

attempt to perform such work.

Proper maintenance and repair is important to safe, reliable operation of the standby system. The

troubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate for

the models described herein. Alternative methods or procedures may pose risk to personal safety and the

safety 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 available

at the time of publication. Briggs & Stratton Corporation reserves the right to change, alter, or otherwise

improve the product or the product manuals at any time without prior notice.

No part of this material may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying or recording by any information storage and retrieval system, without

prior written permission from Briggs & Stratton Corporation.

Page i

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

FA ULT CODE INDICATI ONS ........................ ............................................................................. . 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

Page ii

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

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

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

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

1

SECTION 1 - SAFETY, MAINTENANCE

AND ADJUSTMENTS

In The Interest Of Safety

This repair manual contains safety information

that is designed to:

• Make you aware of hazards associated

with engines.

• Inform you of the risk of injury associated

with those hazards.

• Tell you how to avoid or reduce the risk

of injury.

The Safety Alert Symbol

The safety alert symbol ( ) is used to identify

safety information about hazards that can result

in personal injury.

A signal word (DANGER, WARNING, or CAUTION)

is used with the alert symbol to indicate the

likelihood and 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.

WARNING indicates a hazard which, if

not avoided, could result in death or

serious injury.

CAUTION indicates a hazard which, if

not avoided, might result in minor or

moderate injury.

CAUTION: When this signal word is used

without the alert symbol, it indicates a situation

that could result in damage to the engine.

• Prior to work, read and understand the

section(s) of this manual that pertain to

the job. Follow all safety warnings.

• Wear suitable eye protection.

• When servicing engines or equipment,

prevent accidental starting by

disconnecting control panel fuse, spark

plug wire from the spark plug(s), and

disconnect negative battery cable.

• Disconnect all sources of supply voltage

before servicing the generator.

WARNING

Before attempting to service this equipment,

read and understand this manual and the

operating instructions of the equipment

Failure to follow instructions could result in

DEATH, SERIOUS INJURY (including

paralysis) or property damage.

Explosion

Fire Electrical

Shock

Toxic

Fumes

Rotating

Parts

Hot Surface

Auto Start

Explosive

Pressure

Chemical

Burn

Lift Hazard Read

Manual

HAZARD SYMBOLS AND MEANINGS

2

1

WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects, or

other reproductive harm.

WARNING

Storage batteries give off explosive

hydrogen gas during recharging.

Slightest spark will ignite hydrogen

and cause explosion.

Battery electrolyte fluid contains acid

and is extremely caustic.

Contact with battery contents will

cause severe chemical burns.

A battery presents a risk of electrical

shock 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 several

minutes 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.

WARNING

Running engine gives off carbon mon-

oxide, and odorless, colorless,

poison gas.

Breathing carbon monoxide can

cause 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.

WARNING

Generator produces hazardous volt-

age.

Failure to properly ground generator

can result in electrocution.

Failure to isolate generator from

power utility can result in death or

injury to electric utility workers due to

backfeed 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 is

operating, 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 the

source of electrical power and contact the

local authorities. Avoid direct contact

with the victim.

• Despite the safe design of the home gen-

erator, operating this equipment impru-

dently, neglecting its maintenance, or

being careless can cause possible injury

or death.

• Remain alert at all times while working on

this equipment. Never work on the equip-

ment when you are physically or mentally

fatigued.

• Before performing any maintenance on

the generator, disconnect the battery

cable indicated by a NEGATIVE, NEG, or

(-) first. When finished, reconnect that

cable last.

• After your home generator is installed, the

generator may crank and start without

warning any time there is a power failure.

To prevent possible injury, always set the

generator’s system switch to OFF AND

remove the 15 Amp fuse BEFORE work-

ing on the equipment.

3

1

WARNING

Propane and Natural Gas are

extremely flammable and explosive.

Fire or explosion can cause severe

burns or death.

• Install the fuel supply system according to

N.F.P.A 37 and other applicable fuel-gas

codes.

• Before placing the home generator into

service, the fuel system lines must be

properly purged and leak tested.

• After the generator is installed, you should

inspect 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. Ensure

that no combustible materials are left in

the generator compartment. Keep the

area near the generator clean and free of

debris.

WARNING

Contact with muffler area can result in

serious burns.

Exhaust heat/gases can ignite com-

bustibles or structures, causing a fire.

• DO NOT touch hot parts and AVOID hot

exhaust gases.

• Allow equipment to cool before touching.

• DO NOT install the generator closer than

5 feet (1.5m) from any combustibles or

structures with combustible walls having a

fire resistance rating of less than 1 hour.

WARNING

Starter and other rotating parts can

entangle hands, hair, clothing, or

accessories.

• NEVER operate generator without protec-

tive housing or covers.

• DO NOT wear loose clothing, jewelry, or

anything that may be caught up in the

starter or other rotating parts.

• Tie up long hair and remove jewelry.

CAUTION

Installing the control panel’s 15A fuse

could cause the engine to start.

• DO NOT install this fuse until all plumbing

and wiring has been completed and

inspected.

CAUTION

Excessively high operating speeds increase

risk 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.

CAUTION

Avoid prolonged or repeated skin contact with

used motor oil.

• Used motor oil has been shown to cause

skin cancer in certain laboratory animals.

• Thoroughly wash exposed areas with

soap and water.

4

1

Standby Safety Practices

• This manual contains important safety

messages. Read these carefully and

understand them before proceeding with

maintenance and repairs.

• Become familiar with the Home

Generator System. Know its

applications, its limitations, and any

hazards involved.

• This unit must not be modified for any

application other than that for which it

was designed. If you have any questions

about the home generator System, ask

the dealer or consult Briggs and Stratton.

• Never handle any kind of electrical cord

or device while standing in the water,

while barefoot, or while hands and feet

are wet.

• Worn, bare, frayed, or otherwise

damaged electrical cord sets should not

be used with the Home Generator

System. Using a defective cord may

result is an electrical shock or damage to

the test equipment and/or the unit.

• The Home Generator System requires an

adequate supply of cooling air for

continued proper operation. Never allow

the free flow of cooling air into or out of

the unit to be obstructed in any way.

• Home Generator Systems produce

powerful voltages that can cause

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 manual.

• Never manually start or stop this unit with

electrical loads connected to the

receptacles and turned ON. Start the

engine and allow it to stabilize before

connecting any electrical loads. Turn

OFF and disconnect all electrical loads

before shutting down the generator.

• The manufacturer cannot anticipate

every circumstance that might involve or

constitute a hazard. Warnings in

manuals, warnings on hang tags, and

labels affixed to the unit are NOT all-

inclusive. Do not handle, operate, or

service the unit using a procedure or

method that is not specifically

recommended by the manufacturer.

CAUTION

Exceeding generators wattage/amperage

capacity can damage generator and/or electri-

cal devices connected to it.

• See Essential Circuits in the Operator’s

manual.

• Start generator and let engine stabilize

before connecting electrical loads.

CAUTION

Improper treatment of generator can damage

it and shorten its life, or result in personal

injury.

• 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 Control

Panel doors must be installed whenever

the unit is running.

• DO NOT expose generator to excessive

moisture, dust, dirt, or corrosive vapors.

• Despite the safe design of the home gen-

erator, operating this equipment impru-

dently, neglecting its maintenance or

being careless can cause possible injury

or death.

• DO NOT start engine with air cleaner

removed.

• DO NOT insert any objects through the

cooling slots.

• DO NOT use the generator or any of its

parts as a step. Stepping on the unit can

cause stress and break parts. This may

result in dangerous operating conditions

from leaking exhaust gases, fuel leakage,

oil leakage, etc.

• If connected devices overheat, turn them

off and disconnect them from generator.

• Shut off generator if:

-electrical output is lost;

-equipment sparks, smokes, or emits

flames;

-unit vibrates excessively.

5

1

ACCESS TO THE GENERATOR

The home generator is equipped with an

enclosure that has four access doors (Figure 1).

The doors are named for a significant component

located behind them, as follows:

• Control Panel Door

• Coolant Fill Door

• Battery Door

• Exhaust Door

Each Home Standby Generator System is

equipped with two identical keys. These keys fit

all the doors.

NOTE: The Coolant Fill, Battery and Control

Panel doors must be installed whenever the unit

is running, or the generator may overheat.

Figure1

Removing An Access Door

1. Insert key into lock of access door handle you

wish to open and turn one quarter turn

counterclockwise. Remove key. Handle will

remain unlocked until you relock it.

2. Grasp door’s handle and turn one quarter turn

counterclockwise to open.

3. Coolant Fill door is unlocked in the same

manner. It can be used for adding coolant or

engine oil.

NOTE: The enclosure also includes muffler and

radiator access panels, used for cleaning those

components. Those panels should remain closed

at all other times.

Installing An Access Door

1. 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.

WARNING

Contact with muffler area can result in

serious burns.

• DO NOT touch hot parts and AVOID hot

exhaust gases.

• Allow equipment to cool before touching.

6

1

GENERATOR COMPONENTS

NOTE: Generator is shown with access door removed.

A - Oil Dip Stick - Used to check the engine oil

level.

B - Engine Label - Identifies engine model and

type.

C - Oil Fill Cap - Remove to service the engine

with recommended oil.

D - Thermostat - Allows the engine to heat up

quickly, and then to keep the engine at a con-

stant temperature. It does this by regulating the

amount of coolant that goes through the radiator.

E - Coolant Recovery Bottle - Provides visual

indicator of engine coolant level.

F - Oil Filter - Filters engine oil to prolong sys-

tem life.

G - Oil Drain Plug - Provided to facilitate oil

changing.

H - Ignition Coil - Amplifies the voltage of elec-

tricity supplied to the ignition system.

J - Battery Negative Cable - Cable connects

negative battery terminal to various electrical cir-

cuit and to the engine for starting.

K - Oil Pressure Switch - Monitors engine oil

pressure when the engine is running. Indicates a

drop 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 over

the engine to start it.

M - Battery Fuse Holder - Provides over-current

protection 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 fluid

flow.

P - Generator Ground - Located on the frame

below the generator circuit breaker cover. If

required by local codes, should ONLY be used

for a ground rod. See System Control Panel for

other Ground locations.

R - Unit Data Decal - Identifies unit by model

and serial number.

S - Stub In Location - Located in bottom of cir-

cuit breaker enclosure for power cable stub in

location. Panel is removable to allow easy hole

cutting for conduit.

T - Circuit Breaker Enclosure - Equipped with

removable bottom to assist with conduit connec-

tion.

U - Automatic Voltage Regulator - Access hole

for voltage regulator adjustment.

V - Control Panel - Used for various tests, oper-

ation, and maintenance functions. See System

Control Panel on the next page.

7

1

NOTE: Circuit breaker cover is removed for

illustration purposes.

A - Circuit Breaker — Protects the system from

shorts and other over-current conditions. Must be ON

to 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 exercise

cycle start time and day-of-the-week. Must be reset if

the fuse is removed or the battery is disconnected.

D- Manual Over-Ride Button — With the system

switch in AUTO position, push the manual over-ride

switch to start the generator. To turn off the generator,

push and hold the manual over-ride switch again until

engine stops.

E - 15 Amp Fuse — Protects the home generator DC

control circuits. If the fuse has ‘blown’ (melted open) or

was removed, the engine cannot crank or start.

F - System Switch — This two-position switch is the

most important control on the system and is used as

follows:

• “AUTO” position is the normal operating

position. If a utility power outage is sensed,

the system will start the generator. When

utility power is restored, AUTO lets the

engine stabilize internal temperatures, shuts

off the generator, and waits for the next

utility power outage.

• “OFF” position turns off running

generator, prevents unit from starting

and resets any detected faults.

G - Digital Display — Displays the total number of

hours the generator has been running and fault codes.

Used to schedule maintenance tasks and for

troubleshooting operational problems with the home

generator. All fault conditions are described in Fault

Description System.

H - Ten Pin Connection — Low Voltage connection

to signal fault contacts, transfer switch communication,

remote LED and auxiliary 12VDC power are made to a

removable ten-pin connector plug.

J - Generator Ground Lug — Located next to the

circuit breaker and should meet most codes,

standards, and regulations.

K - Utility Circuit Connection — Delivers power to

the generator’s circuit board (within internal battery

trickle charge) and water heater. When the power on

these leads is lost, the generator will start. Fuse

protected. Replace the fuse(s) only with identical

fuse(s).

L - Generator AC Lugs — Connection for generator

load(s).

8

1

NOTE: Generator is shown with access door

removed.

A - Over Temperature Switch - Switch for auto-

matically making or breaking an electrical circuit

at predetermined temperature. Will signal the

system control panel to shut down the generator

when the engine coolant reaches a critical level.

B - RPM Sensor - A permanent magnet built into

the sensor provides a magnetic field at the base

of the sensor. As each tooth of the flywheel

passes through the magnetic field, a signal (volt-

age pulse) is generated. The engine control unit

uses this to monitor engine speed to maintain a

specific generator frequency.

C - Air Cleaner - Protects engine by filtering dust

and debris out of intake air.

D - Alternator Data Plate - Lists alternator data

specific to the Marathon alternator assembly.

E - Battery - Stores and supplies electrical

energy. The manufacturer does not supply the

battery.

F- Engine Warmer - An electric heater that

heats the engine by keeping the engine coolant

warm to ease starting in cold weather. Con-

nected to utility power and fully automatic.

9

1

GENERATOR CLEARANCES

General Location Guidelines

• Install the unit outdoors ONLY.

• Place the unit on a prepared concrete

slab that is flat, level, and has provisions

for water drainage.

• Install the unit in a location where sump

pump discharge, rain gutter down

spouts, roof run-off, landscape irrigation,

or water sprinklers will not flood the unit

or spray the enclosure and enter any air

inlet or outlet openings.

• Install the unit where the location of any

services such as phone, electrical, fuel,

air conditioning, irrigation, including

covered, concealed and underground

services will not be affected or

obstructed.

• Install the unit where air inlet and outlet

openings will not become obstructed by

leaves, grass, snow, sand, etc. If

prevailing winds will cause blowing or

drifting you may need to construct a

windbreak to protect the unit.

• Install the generator as close as possible

to the transfer switch and fuel supply to

reduce the length of wiring, conduit, and

piping.

IMPORTANT: Laws or local codes may regulate

the distance to the fuel supply.

The Minimum clearances from aerial view of

generator (A) to combustible (C,D) materials is

shown in Figure 1.

• These distances are provided to give

generator location guidance relative

ONLY to combustibles, generator

cooling, and maintenance.

• The minimum distances in the figure are

as shown. All four sides of the generator

cannot be enclosed or restricted, even if

the minimum distances are maintained.

DO NOT connect (C) to (D).

• A roof cannot be constructed over the top

of the generator.

• Exhaust (B) is directed out the top of the

generator and must not be allowed to

accumulate.

WARNING

Running engine gives off carbon mon-

oxide, and odorless, colorless, poi-

son gas.

Breathing carbon monoxide can

cause 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.

WARNING

Exhaust heat/gases can ignite com-

bustibles or structures, causing a fire.

• DO NOT install the generator closer to 5

feet (1.5m) from any combustibles or

structures with combustible walls having a

fire resistance rating of less than 1 hour.

10

1

SYSTEM CONNECTION

Low Voltage (LV) connections to signal fault contacts, transfer switch communications, remote LED and

auxiliary 12VDC power are made to a removable ten-pin connector plug. Compare this illustration with the

location of these important connections:

A - 10 Pole Connector Plug

B - Fault Contacts — Use NO, COM and NC for operating a siren, light, optional GenAlert, etc. to alert

you 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 communication

interface.

D - Remote LED Output — Used to connect to the remote LED supplied with the generator. The remote

LED 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.

11

1

GENERATOR AC CONNECTION

SYSTEM

A single-phase, three-wire AC connection

system is used on the home generator. The

stator assembly consists of a pair of stationary

windings with two leads brought out of each

winding. The junction of leads T2 and T3 forms

the neutral lead, as shown schematically and as

wiring diagram below. A complete schematic and

wiring diagram can be found later in this manual.

NOTE: Neutral is not bonded to ground at

generator.

Grounding the Generator

Ground the home generator per applicable

codes, standards and regulations. There are two

generator Ground lug locations. The one inside

the alternator junction box next to the circuit

breaker is the primary lug and should meet most

applications. The second Ground lug is located

on the frame below the generator circuit breaker

cover, and should ONLY be used for a ground

rod located at the generator, if required by local

codes. See Controls for location.

Utility Circuit Connection

“240V Utility” leads must be routed in conduit.

The “240V Utility” leads deliver power to the

generator’s circuit board and water heater. This

power also charges the battery. When power on

these leads is lost, the generator will start.

Fault Detection System

The generator may have to run for long periods

of time with no operator present. For that reason,

the system is equipped with sensors that

automatically shut down the generator in the

event of potentially damaging conditions, such

as low oil pressure, high water temperature, over

speed, and other conditions. Refer to Fault

Detection System for more detailed information.

12

1

FUEL SUPPLY

Depending on the generator model number, the

home standby generator was manufactured and

shipped to run on natural gas or liquid propane

vapor. No matter which type of fuel the generator

was manufactured to run on, it can be field

converted to operate on either type of fuel. When

troubleshooting, engine performance is

dependent on receiving the specific pressure

and volume of fuel under varying load conditions

with all gas appliances turned on and operating.

For fuel consumption and pressure

specifications, consult the installation manual.

For proper engine function, factors that are

inherent to each of these fuels, your location and

the duration of possible utility interruptions are

important considerations in the following fuel

guidelines:

• Use clean, dry fuel, free of moisture or

any particulate material. Using fuels

outside the following recommended

values may cause performance

problems.

• For engines set up to run on propane

vapor (LP), commercial grade HD5

propane with a minimum fuel energy of

2500 BTUs/ft3 with maximum propylene

content of 5% and butane and heavier

gas content of 2.5% and minimum

propane content of 90%.

Power Decrease at High Altitude or High

Temperature

Air density is less at high altitudes, resulting in

less available engine power. Specifically, engine

power 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 must

be considered when determining total generator

load.

WARNING

Propane and Natural Gas are

extremely flammable and explosive.

Fire or explosion can cause severe

burns or death.

• The home generator is equipped with an

automatic safety gas “fuel shut-off” valve.

• DO NOT operate the equipment if the “fuel

shut-off” valve is missing or inoperative.

WARNING

Propane and Natural Gas are

extremely flammable and explosive.

Fire or explosion can cause severe

burns or death.

• Install the fuel supply system according to

N.F.P.A 37 and other applicable fuel-gas

codes.

• Before placing the home generator into

service, the fuel system lines must be

properly purged and leak tested.

• After the generator is installed, you should

inspect 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. Ensure

that no combustible materials are left in

the generator compartment. Keep the

area near the generator clean and free of

debris.

13

1

SETTING THE EXERCISE TIMER

The home generator 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 an utility power outage occurs).

A button on the control panel is labeled “Set

Exercise” (see System Control Panel). The

specific day and the specific time of day this

button is pressed is programmed into the control

board memory. This date and time is then used

to automatically initiate the system exercise

cycle. The “Set Exercise” legend on the control

panel 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 the

button is pressed for three seconds, then “SET

EXERCISE” will illuminate for 5 seconds, and

finally 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 unit

will run an immediate exercise cycle and an

exercise cycle will occur every following Sunday

at 10:100 AM (+/- 1/2 hour).

NOTE: “Set Exercise” will only work if the unit is

in the Automatic mode and this exact procedure

is followed. The exerciser will need to be re-set

whenever the 15 Amp fuse is removed or

changed, or if the 12 Volt DC battery is

disconnected.

If you want to change the day and time the unit

exercises, simply perform the “Set Exercise”

procedure at the exact weekday and time you

want it to take place.

GENERATOR MAINTENANCE

Generator maintenance consists of keeping the

unit clean. Operate the unit in an environment

where it will not be exposed to excessive dust,

dirt, moisture or any corrosive vapors. Cooling air

louvers on the enclosure must not become

clogged with snow, leaves, or any other foreign

material.

Check the cleanliness of the unit frequently and

clean when dust, dirt, oil, moisture or other

foreign substances are visible on its exterior/

interior surface.

NOTE: DO NOT use direct spray from a garden

hose to clean generator. Water can enter the

engine and generator and cause problems.

Engine Maintenance

An engine manual was packaged with this

system. Please refer to it for all engine-related

maintenance topics. However, proper engine

cooling and lubrication are so important we also

reference them.

Engine Oil

The system is filled with the recommended non-

synthetic oil (API SL 10W-30W). This allows for

proper system operation in a wide range of

temperature and climate conditions.

NOTE: Refer to the engine operator’s manual for

the recommended oil change intervals.

Shown here is the oil drain location (B) and the

oil filter (A).

Figure2

14

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Changing Engine Oil

KEEP OUT OF THE REACH OF CHILDREN.

DON’T POLLUTE. CONSERVE RESOURCES.

RETURN USED OIL TO COLLECTION

CENTERS.

1. Put SYSTEM switch in OFF. Remove 15 Amp

fuse. Disconnect negative battery cable from

negative battery terminal.

2. Change oil while the engine is still warm from

running, as described in the engine operator’s

manual.

To fill your engine with oil:

Follow the oil grade recommendation and oil fill

instructions given in the engine operator’s

manual.

To make the task of adding oil more convenient,

we recommend the use of a funnel attached to

the length of tubing long enough to reach from

the Coolant Fill door to the oil fill opening on the

engine valve cover. Recheck oil level,reconnect

battery, install fuse, put in AUTO and reset

exercise timer when complete.

Engine Coolant System

With the engine cold, check the coolant level in

the coolant recovery bottle, seen inside the

Control Panel door. Maintenance instructions for

engine coolant are found in the engine operator’s

manual.

BATTERY

Charging the Battery

If it is necessary to charge the battery, proceed

as 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 2

Amps until battery holds 12 Volts.

NOTE: With the battery installed and utility

power available to the transfer switch, the battery

receives a trickle charge whenever the engine is

not running. It may take up to 72 hours to fully

charge a discharged battery with the trickle

charge. The trickle charge is not able to recharge

a battery that is completely discharged.

CAUTION

Avoid prolonged or repeated skin contact with

used motor oil.

• Used motor oil has been shown to cause

skin cancer in certain laboratory animals.

• Thoroughly wash exposed areas with

soap and water.

NOTICE

Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended coolant or oil will result in equipment

failure.

• Refer to Maintenance in the Operator’s

Manual and engine manual for coolant

and oil fill information.

• Damage to equipment resulting from fail-

ure to follow this instruction will void

engine and generator warranty.

NOTICE

Failure to disconnect the negative battery

cable 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.

15

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5. Connect negative battery cable to negative

battery terminal (indicated by NEGATIVE,

NEG, or (-)).

6. Ensure hardware on both positive and

negative 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 Battery

If it is necessary to service the battery, proceed

as 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 and

negative 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 exterior

surfaces clean.

• Use a soft bristle brush to loosen caked

on dirt, oil, etc.

• Use a vacuum cleaner to pick up loose

dirt and debris.

• Use low pressure air (not to exceed 25

psi) to blow away dirt. Inspect cooling air

slots and openings on the generator.

These openings must be kept clean and

unobstructed.

WARNING

Storage batteries give off explosive

hydrogen gas during recharging.

Slightest spark will ignite hydrogen

and cause explosion.

Battery electrolyte fluid contains acid

and is extremely caustic.

Contact with battery contents will

cause severe chemical burns.

A battery presents a risk of electrical

shock 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 several

minutes 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.

CAUTION

Installing the control panel’s 15A fuse

could cause the engine to start.

• DO NOT install this fuse until all plumbing

and wiring has been completed and

inspected.

NOTICE

Improper treatment of generator can damage

it and shorten its life.

• DO NOT expose generator to excessive

moisture, dust, dirt, or corrosive vapors.

• DO NOT insert any objects through cool-

ing slots.

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