Briggs & Stratton 040213 User manual

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15000 WATT HOME GENERATOR SYSTEM

SERVICE & TROUBLESHOOTING MANUAL

MODELS 040213 & 040234

Part# 276351GS - June 2006

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FORWARD

This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and

company service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar

products, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in the

recommended servicing procedures for these products, which includes the use of mechanics hand tools and any

special tools that might be required.

Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems.

The troubleshooting, testing, service and repair procedures described in this guide are effective methods of

performing such operations.

We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a

service might be performed, nor of any possible hazards and/or results of each procedure or method. We have not

undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by the

manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be endangered by the

service or operating procedure selected.

All information, illustrations, and specifications contained in this guide are based on the latest production information

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

otherwise improve the product at any time without prior notice.

Some components or assemblies of the product described in this guide may not be considered repairable.

Disassembly, repair and reassembly of such components may not be included in this guide.

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Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)

Table Of Contents

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15000 WATT HOME GENERATOR SYSTEM

SECTION 1 - GENERAL INFORMATION ... ............................................................................11

ACCESS TO THE GENERATOR .......................................................................................................11

To remove an access door: ........................................................................................................................... 11

To install an access door: .............................................................................................................................. 11

GENERATOR COMPONENTS ..........................................................................................................12

SYSTEM CONTROLS ........................................................................................................................13

GENERATOR CLEARANCES ...........................................................................................................14

ENGINE MAINTENANCE ...................................................................................................................14

Checking Oil Level ......................................................................................................................................... 14

Changing the Oil and Oil Filter ....................................................................................................................... 14

Replacing the Spark Plugs ............................................................................................................................ 15

Service Air Cleaner ........................................................................................................................................ 15

Valve Lash ..................................................................................................................................................... 15

Cooling Fins ................................................................................................................................................... 15

FUEL SUPPLY ...................................................................................................................................15

Reconfigure The Fuel System ....................................................................................................................... 16

GENERATOR AC CONNECTION SYSTEM ......................................................................................16

SYSTEM CONNECTIONS .................................................................................................................17

Wiring For The 2-Pin Connector: ................................................................................................................... 17

Wiring For The 10-Pin Connector: ................................................................................................................. 17

SETTING THE EXERCISE TIMER ....................................................................................................18

CONTROL MODULE ASSEMBLY (CMA) ..........................................................................................18

Power During CMA Fault Conditions ............................................................................................................. 18

Access To The CMA Board ........................................................................................................................... 19

CMA Connections .......................................................................................................................................... 19

FAULT CODE INDICATIONS .............................................................................................................20

Fault Code Index: .......................................................................................................................................... 20

Resetting The Fault Code Detection System ................................................................................................. 20

STOPPING THE SYSTEM FOR MAINTENANCE .............................................................................20

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)

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SECTION 2 - TROUBLESHOOTING INFORMATION ............................................................23

(FC_1)

DEAD UNIT/LOW BATTERY VOLTAGE: ..........................................................................................23

Test 1

Check Battery: ................................................................................................................................................23

Test 2

Check DC Amperage at Battery: ....................................................................................................................23

Test 3

Check AC Voltage Input: ................................................................................................................................24

Test 4

Measure DC Output Voltage at the CMA .......................................................................................................24

(FC_2)

LOW OIL PRESSURE: .......................................................................................................................27

Test 1

Measure for Short-To-Ground ........................................................................................................................27

Test 2

Check Engine Oil Pressure ............................................................................................................................28

Test 3

Check Oil Pressure Switch .............................................................................................................................28

(FC_3)

LOW OUTPUT VOLTAGE: .................................................................................................................31

Test 1

Measure Circuit Breaker Load-Side Voltage: .................................................................................................31

Test 2

Measure Voltage at E1 and E2 ......................................................................................................................31

Test 3

Measure Circuit Breaker Line Voltage: ..........................................................................................................32

(FC_4)

ENGINE FAILS TO START: ...............................................................................................................35

Troubleshooting Engine Start Failures: ..........................................................................................................35

Test 1

Check Fuel Delivery System ..........................................................................................................................35

Test 2

Visually Inspect Generator .............................................................................................................................35

Test 3

Check Fuel Supply Pressure ..........................................................................................................................36

Test 4

Check Fuel Solenoid. .....................................................................................................................................36

Test 5

Check Fuel Regulator ....................................................................................................................................38

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)

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Test 6

Check Ignition Spark: ..................................................................................................................................... 38

Test 7

Check Battery Components ........................................................................................................................... 38

Test 8

Check Starter Contactor Signal ..................................................................................................................... 39

Test 9

Check CMA Board Output ............................................................................................................................. 40

Test 10

Check Starter ................................................................................................................................................. 40

(FC_5)

UNDER FREQUENCY: ......................................................................................................................43

Test 1

Check No Load & Full Load Frequency: ........................................................................................................ 43

Test 2

Measure Frequency at E1 & E2 ..................................................................................................................... 44

(FC_6)

OVER FREQUENCY: .........................................................................................................................45

(FC_7)

HIGH OIL TEMPERATURE: ...............................................................................................................47

Test 1

Check Over Temperature Switch (OTS): ....................................................................................................... 47

Test 2

Check Wire #95 ............................................................................................................................................. 47

(FC_8)

TRANSFER SWITCH FAILURE: ........................................................................................................48

15kW WINDING TEST INDEX ...........................................................................................................49

CHECKING THE STATOR WINDING THROUGH THE HARNESS ..................................................50

CHECKING THE EXCITATION WINDING IN THE GENERATOR ....................................................50

CHECKING THE STATOR POWER WINDING .................................................................................51

CHECKING THE ROTOR WINDING .................................................................................................51

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)

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SECTION 3 - UNIT DISASSEMBLY ........... ............................................................................53

REMOVING THE ACCESS DOORS ..................................................................................................53

REMOVE THE ROOF ASSEMBLY ....................................................................................................53

REMOVE THE EXHAUST BULKHEAD .............................................................................................53

REMOVE THE CONTROL PANEL BULKHEAD ................................................................................54

Remove Battery .............................................................................................................................................54

Remove Control Panel ...................................................................................................................................54

Disconnect Fuel Solenoid ..............................................................................................................................55

REMOVE THE MUFFLER ASSEMBLY .............................................................................................56

REMOVE COOLING DUCTS .............................................................................................................56

REMOVE THE STATOR ASSEMBLY ................................................................................................56

REMOVING THE ROTOR ASSEMBLY .............................................................................................59

INSPECTING THE ROTOR ASSEMBLY ...........................................................................................59

REMOVING THE ENGINE ADAPTOR ...............................................................................................60

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)

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SECTION 4 - FINAL ADJUSTMENTS AND SPECIFICATIONS ..............................................61

OERATIONAL TESTS ........................................................................................................................61

Manual Operation Test (No Load) ................................................................................................................. 61

Automatic Operation Test (Load Transfer) .................................................................................................... 62

Generator Load Test (Full Rated Electrical Capacity And Fuel Consumption) .............................................. 62

SPECIFICATIONS ..............................................................................................................................64

WIRING DIAGRAM - MODEL 071013 - LOAD CONTROL CENTER ................................................65

SCHEMATIC - MODELS 040213 & 040234 - GENERATOR .............................................................66

WIRING DIAGRAM - MODELS 040213 & 040234 - GENERATOR ...................................................67

SCHEMATIC - MODELS 1813 & 1814 - TRANSFER SWITCH .........................................................68

WIRING DIAGRAM - MODELS 1813 & 1814 - TRANSFER SWITCH ...............................................69

SCHEMATIC - MODELS 071008 & 071009 - TRANSFER SWITCH .................................................70

WIRING DIAGRAM - MODELS 071008 & 071009 - TRANSFER SWITCH .......................................71

SCHEMATIC - MODELS 071010 & 071011 - TRANSFER SWITCH .................................................72

WIRING DIAGRAM - MODELS 071010 & 071011 - TRANSFER SWITCH .......................................73

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)

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Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW)

Section 1 - General Information

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SECTION 1 - GENERAL INFORMATION

ACCESS TO THE GENERATOR

The 15kW Home Standby Generator System is equipped

with an enclosure that has three access doors (Fig.1).

The doors are named for the significant component(s)

located behind them. Starting with the side that has the

fuel connection and proceeding clockwise, the doors are

named:

• Oil Fill Door

• Control Panel Door

• Oil Drain Door

Each Home Standby Generator System is equipped with

two identical keys. These keys fit all the doors.

To remove an access door:

• Insert a key into the lock of the access door you

wish to remove and turn one quarter turn

counterclockwise.

• Open the latch with a quarter turn

counterclockwise.

• Open the door enough to clear its jambs and lift

the door from its hinges.

NOTE: When removing more than one door at a

time, it’s a good idea to mark the doors for proper

fit when reinstalling.

To install an access door:

• Mount the door hinge barrels on their respective

pins and close.

• Turn latch a quarter turn clockwise.

• Lock the door with the key.

Fig. 1 - Generator Access Doors

CAUTION: Do not operate the standby

generator for extended periods without all the

doors installed and closed. Failure to do so will

cause overheating.

Fuel Inlet Fitting

Lifting Holes

Oil Fill Door

Control Panel Door

Oil Drain Door

Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW)

Section 1 - General Information

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GENERATOR COMPONENTS

15 Amp Fuse - Protects the DC control circuits.

Air Cleaner- Protects engine by filtering dust and debris out of

intake air.

Battery - 12 Volt DC, AGM Type, 55 Amp-Hour sealed battery

provides power to start the engine. Battery receives trickle

charge whenever the generator is not running and when utility is

present.

Control Panel - Used for various tests, operation and

maintenance functions. (See “SYSTEM CONTROLS” on

page 13.)

Engine Label - Identifies engine model and type.

Exhaust Port - High performance muffler lowers engine noise

to comply with most residential codes.

Oil Dipstick - Used to check engine oil level.

Oil Drain Hose- Provided to facilitate changing oil.

Oil Fill Cap- Remove to service engine with recommended oil.

Oil Filter- Filters engine oil to prolong engine life.

Unit Data Decal - Identifies unit by model number, revision

and serial numbers.

Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW)

Section 1 - General Information

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SYSTEM CONTROLS

15 Amp Fuse - Protects the Home Standby Generator

System DC control circuits. If the fuse has melted open or

was removed, the engine cannot crank or start. Replace

the fuse using only an identical ATO 15A fuse.

Circuit Breaker - Protects the system from over

current conditions and must be in the ON position to

supply power to the automatic transfer switch.

Digital Display - Used as an hour meter and to show

various fault indications. (See “FAULT CODE

INDICATIONS” on page 20.)

MANUAL OVER-RIDE- Used to start the engine

manually. Push and hold to start and shut unit down.

(SYSTEM switch must be in AUTO for MANUAL-

OVERIDE to operate.

Service Tool - For use by qualified service technicians

only.

SET EXERCISE - Used to set the exercise cycle start

time and day of the week. Exercise cycle only occurs in

the

AUTO mode.

SYSTEM - This two position switch operates as follows:

• AUTO position is the normal operating mode. If a

utility power outage is sensed, the generator will start

automatically. When utility power is restored, the

generator will shut down and is ready for the next

utility power outage.

• OFF position turn off a running generator, prevents

generator from starting and resets any fault

indications.

Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW)

Section 1 - General Information

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GENERATOR CLEARANCES

The generator enclosure should be a minimum of 5 ft.

(1.52 meter) from any combustible material. At least 5 ft.

(1.52 meter) of access room all around the enclosure

should be available. The unit exhaust grill should be at

least 10 ft. (3.05 meter) from any building opening

(window, door, vent etc.), and the exhaust gases should

not be able to accumulate in any occupied area (Fig. 2).

Fig. 2 - Generator System Clearances

ENGINE MAINTENANCE

NOTE: Detailed servicing information about this

Briggs & Stratton engine is available in the

“VANGUARD™ V-Twin OHV Repair Manual

(#272144).”

Checking Oil Level

Before placing the standby generator in service and at

the recommended maintenance interval, check the

engine oil level, as follows:

1. Remove Oil Fill door. Clean area around oil fill and

dipstick locations.

2. Remove dipstick. Wipe with clean cloth.

3. Insert dipstick fully. Remove and check oil level.

If oil level is low, remove oil fill cap and slowly add

recommended oil to bring level to

Full mark on dipstick

(Fig.3).

Fig. 3 - Oil Dipstick Markings

A reusable oil spout that fits most oil bottles is supplied to

make it easier to pour oil into the engine.

Changing the Oil and Oil Filter

Oil capacity is approximately 2-1/2 quarts (79 ounces or

2.3 liters) when changing oil and filter. Use only detergent

for service Grade SJ or greater synthetic oil. Change oil

after every 50 operating hours. Replace oil filter every 100

operating hours

.

If you are using this engine under dirty or dusty

conditions or in extremely hot weather, change the oil

more often. Use the following instructions to change the

oil while the engine is still warm:

1. Make sure the SYSTEM switch is set to

OFF.

2. Remove the 15 Amp fuse.

3. Un-clip and wipe the oil drain hose clean with a

rag. Place the oil drain hose into a suitable

container. Grasp the oil drain fitting and push it in

towards the engine. Rotate it counterclockwise to

its stop and pull the fitting outwards. Oil should

begin to flow out of the oil drain hose.

4. After the oil is drained, grasp the oil drain fitting

and rotate it clockwise until it locks in place.

Position the oil drain hose in its storage clip.

5. Place a suitable container beneath the oil filter and

remove the filter.

Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW)

Section 1 - General Information

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6. Coat the o-ring of the new filter with fresh clean

engine oil. Turn the new filter clockwise by hand

until the gasket contacts the filter adapter, then

tighten 1/2 to 3/4 turn more.

7. Fill engine with oil until level is at the

FULL mark

on the dip stick.

8. Install and tighten the oil fill cap.

9. Run the engine for a minute, stop the engine and

check for oil leakage around the oil filter. Recheck

oil level.

Replacing the Spark Plugs

Replace the plugs every year. Use the recommended

spark plugs gapped for 0.020 in. (0.51 MM).

1. Stop the engine (See “STOPPING THE SYSTEM

FOR MAINTENANCE” on page 20.) and pull the

spark plug wires off of the spark plugs.

2. Clean around the spark plugs and remove them

from the cylinder head.

3. Clean off carbon deposits on the spark plug

electrode using a wire brush or commercial

solvent. Do not blast clean.

4. Set the plug gap as recommended. Install the

correctly gapped spark plugs into the cylinder

heads.

Torque to 15 lb. ft.

Service Air Cleaner

The engine air cleaner is one of the most important

areas to maintain. The engine will not run properly and

will be damaged if it is run with a dirty air cleaner system.

Use only genuine Briggs & Stratton parts. The use of

replacement parts which are not

UL® approved, may

damage the engine. Clean the foam pre-cleaner every

25 hours and the cartridge every 100 hours of operation.

Clean or replace more often in dusty or dirty conditions.

To service the air cleaner components:

1. Remove wing nut from top of air cleaner cover.

2. Remove winged from air filter retainer.

3. Service cartridge by tapping gently on a flat

surface. Do not oil cartridge. Replace if very dirty

or damaged.

4. Reinstall or replace air filter cartridge

5. Reinstall cover.

NOTE: Do not use petroleum solvents, e.g.

kerosene, which will cause the cartridge to

deteriorate. Do not use pressurized air to clean

cartridge. Pressurized air can damage the

cartridge.

Valve Lash

Valve lash must be checked while engine is cold after

every 100 hours of operation. Adjust if necessary (See

“VANGUARD™ V-Twin OHV Repair Manual (#272144).”

Valve lash is: Intake and Exhaust 0.004 - 0.006 in. (0.10

- 0.15 MM.)

Cooling Fins

Periodically, check to make sure the engine cooling fins,

screens and carburetor ducting are free of leaves, grass

or any other type of debris.

FUEL SUPPLY

The following fuel supplies are necessary to ensure

effective generator operation (Fig. 4)

.

Fig. 4 - Fuel Supply & Consumption Table

Models Natural Gas* LPG Vapor**

1/2 Load Full Load 1/2 Load Full Load

125 239 49.62+/- 5% 95.29+/- 5%040213-0 & 040234-0

* = Natural Gas in cubic feet per hour.

** = LPG Vapor in cubic feet per hour.

Fuel Pressures:

NG: 5-7” w.c.

LPG: 11-14” w.c.

These pressures at FULL LOAD with all gas

appliances turned ON.

Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW)

Section 1 - General Information

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NOTE: 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 10°F (5.6°C) above 77°F

(25°C). If the generator is not developing full

power, make sure these factors have been

considered when determining total generator

load output.

Reconfigure The Fuel System

The engine of your Home Standby Generator System is

factory calibrated to run on natural gas (NG). It may also

be operated on liquefied propane gas (LPG). There is no

additional hardware/equipment required to switch

between either fuel. However, LPG fuel inlet pressure

must be between 11 and 14 inches water column.

To reconfigure the fuel system for LPG use:

1. Open the control panel access door.

2. Set the SYSTEM switch to

OFF.

3. Set the generator main circuit breaker

OFF.

4. Remove the 15 Amp fuse.

5. Remove the cap from the fitting marked LPG

above the fuel regulator ( Fig. 5).

6. Remove the fuel supply hose from the NG fitting.

7. Pull hose through hole in sheet metal bulkhead

towards engine.

8. Remove and reverse fuel hose bushing and plug

in sheet metal bulkhead (Plug in top hole, bushing

in bottom hole).

9. Insert fuel hose in bottom hole towards regulator.

10. Install the hose on the LPG fitting.

11. Install the cap on the NG fitting ( Fig. 5).

Fig. 5 - Fuel System Fittings

12. Reinstall the 15 Amp fuse.

13. Set the generator main circuit breaker

ON.

14. Set the SYSTEM switch to

ON.

• Close the control panel access door.

The system is now ready to operate using LPG fuel.

The fuel mixer is set at the factory. No field adjustments

are required.

GENERATOR AC CONNECTION

SYSTEM

A single-phase, three-wire AC connection system is

used in the Home Generator System. The stator

assembly consists of a pair of stationary windings with

two leads brought out of each winding. The two windings

are connected together in series, resulting in a fixed

240VAC, 60Hz output. Stator output leads #11 and #44

are the two hot leads. The junction of leads #22 and #33

form the neutral lead (Fig. 6).

Fig. 6 - System (AC) Connections

Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW)

Section 1 - General Information

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SYSTEM CONNECTIONS

Wiring For The 2-Pin Connector:

240 Volt Utility - Use to hook up the 240V utility leads

from the transfer switch to the generator.

Wiring For The 10-Pin Connector:

Fault Contacts - Use NO, COM and NC to hook up a

siren, light, etc. to alert you in case of a fault. Contacts

reverse state upon a fault condition.

Remote LED Output: - Use this to hook up 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.

Transfer Switch Communication - Use TxRx and TxRx

GND to transfer switch and optional wireless

StatStation

™ to monitor generator functions and for

FC_8 sensing.

+12 Volt DC, .5AMP Output - Internal power supply.

Fault Contacts

Transfer Switch

Communications

Remote LED Output

+12VDC,.5Amp Output

240VAC Utility

10 Pin Connector

2 Pin Connector

Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW)

Section 1 - General Information

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SETTING THE EXERCISE TIMER

The Home Standby Generator System is equipped with

an exercise timer that will start and exercise the system

once every seven days. During this exercise period, the

unit runs for approximately 20 minutes and then shuts

down. Electrical load transfer does not occur during the

exercise cycle (unless a utility power outage occurs).

A switch on the control panel is labeled

SET EXERCISE

(See “SYSTEM CONTROLS” on page 13.).

The

specific day and the specific time of day this switch is

pressed is retained by a memory chip on the Control

Module Assembly (CMA). The day and time is then

referenced by the chip to automatically initiate the

system exercise cycle in seven days.

To perform the set exercise procedure:

1. Make sure the SYSTEM switch is set to

AUTO.

2. Choose the day and time you want your Home

Standby Generator System to exercise.

3. Press and hold down the

SET EXERCISE switch for

three seconds. The LED on the control panel will

flash until “SET EXERCISE” is complete.

4. Release the

SET EXERCISE switch.

Set exercise is complete.

As an example, if you press the

SET EXERCISE switch on

Sunday morning at 10:00 AM, the unit will run an

exercise cycle the following Sunday at 10:00 AM (± 30

minutes).

NOTE: Set exercise will only work if the unit is

in the

AUTO mode and this exact procedure is

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

the 12 VDC battery is disconnected or if you

remove the 15 AMP fuse.

If you want to change the day and time the unit

exercises, simply perform the set exercise procedure on

the exact day and time you want it to take place.

CONTROL MODULE ASSEMBLY (CMA)

The Control Module Assembly (CMA) is a printed circuit

board that is integrated with the control panel of the

Home Standby System. It contains all the logic circuits,

operator controls and system displays necessary to

operate, program and protect the generator. In addition,

it also has an access port for a diagnostic service tool to

aid in troubleshooting external system components and

internal control module failures. The CMA interprets and

monitors electrical inputs from all related circuits

throughout the standby installation.

Before replacing the CMA, all other circuits must be

tested to ensure proper operation. When a failure in the

CMA has been determined, it must be replaced as a

complete assembly.

Functions of the CMA:

• 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 Detection with Automatic Shutdown

• Fault Indication Display (LED)

• Diagnostic access port (SERVICE TOOL)

• Hour Meter

Power During CMA Fault Conditions

When the Home Generator System is in an uncorrected

fault condition, the automatic transfer switch defaults to

UTILITY POWER. This ensures that utility power is

automatically applied to all circuits in the home

-regardless of an uncorrected generator fault.

If the unit fails to exercise at its prescribed time:

• Check the fault indication number displayed on

the generator control panel.

• Perform the SET EXERCISE procedure.

Service & Troubleshooting Guide - Home Generator System - Models 040213 and 040234 (15kW)

Section 1 - General Information

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Access To The CMA Board

The CMA is mounted behind the control panel door

behind the face of the control panel (Fig. 7).

1. Open and/or remove control panel door.

Fig. 7 - Location Of The Control Panel

2. Make sure the SYSTEM switch is set to OFF.

3. Remove the 15 AMP fuse.

4. Remove the circuit breaker cover.

5. Disconnect the 2-pin and 10-pin connectors.

6. Remove the four mounting screws that hold

the face of the control panel (Fig. 8).

Fig. 8 - Control Panel Mounting Hardware

CMA Connections

The CMA is connected to its various circuits through

three connectors that are mounted directly to the circuit

board. One connector has 8 pins , another has two

pins and the other has 10 pins (Fig. 9). All

receptacles have matching halves. The 2-pin plug

supplies 240VAC from UTILITY power. The 10-pin plug

is used for optional generator features. In addition, the

CMA also has connections for E1 and E2 which

sense 240VAC on the generator and four terminals

which can be used for optional battery and engine

warmers.

Fig. 9 - CMA Connector Receptacles And Pins

The 8-Pin Connector

The 8-pin connector is wired to the internal systems of

the unit and is the primary point of measurement for

troubleshooting the Home Standby System. When

directed to measure an electrical value, the location of a

meter probe is shown with an arrow in the picture and

the corresponding pin of the connector is

bold in a graphic illustration. The pin numbering of the

connector is shown with the CMA board exposed

(upsidedown in relation to the schematic) as in (Fig.10).

Fig. 10 - Measuring Electrical Values & Components

115-0005

1

2

3

4

5

6

7

8

Service & Troubleshooting Guide - Home Generator System - Model 040234 (15kW)

Section 1 - General Information

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A detailed illustration of the entire connector, as well as

the functions of each individual pin, is given in (Fig. 11).

Fig. 11 - The 8-Pin Connector And Its Functions

FAULT CODE INDICATIONS

The generator may have to run for long periods of time

with no operator present. For that reason, the CMA is

equipped with sensing circuits that automatically shut

down the generator in the event of potentially damaging

conditions.

A digital display is provided on the face of the control

panel to annunciate the type of failure (Fault Code) that

has occurred. In addition, there is an optional LED that

can be mounted elsewhere in the system to provide a

remote indication of generator failures.

When the CMA senses a condition that prevents the

generator from functioning properly, it shuts down the

generator and induces the digital display on the unit to

indicate

“FC_#” (# representing the number of the fault

code detected). Simultaneously, it signals the remote

LED to flash in a sequence of blinks that correspond to

the fault code indicated on the digital display.

Fault Code Index:

1. (FC_1) Low Battery Voltage

2.

(FC_2) Low Oil Pressure

3.

(FC_3) Low Output Voltage

4.

(FC_4) Engine Fails To Start

5.

(FC_5) Low Frequency

6.

(FC_6) Engine Over-speed

7.

(FC_7) High Oil Temperature

8.

(FC_8) Transfer Switch Failure

For example,

“FC_1” on the digital display would indicate

a low battery voltage condition and the remote LED

would flash once, pause, flash once again and continue

so on until reset or the condition is corrected.

Resetting The Fault Code Detection System

An operator or technician must reset the fault detection

system each time it activates.

To do so:

• Place the SYSTEM switch in the

OFF position for

5 seconds or more.

• Place the SYSTEM switch in the

AUTO position.

If the fault is not corrected, it will be detected again and

the unit will again go into Auto Shutdown with the same

fault code indication(s).

STOPPING THE SYSTEM FOR

MAINTENANCE

1. Ensure that the main line disconnect (MLD) is ON

and power is supplied to the UTILITY

CONNECTION lugs of the transfer switch.

2. Set the generator’s SYSTEM switch to

OFF.

3. Set the generator’s main circuit breaker to its

OFF

position.

Remove the 15 AMP fuse, as appropriate to your

maintenance needs.

1

2

3

4

5

6

7

8

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

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Briggs & Stratton 040213 User manual

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