Briggs & Stratton 1938 Manuel utilisateur

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.

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

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

permission in writing from Briggs & Stratton Corporation.

Service&TroubleshootingGuide- HomeGeneratorSystems

Model1938(lOkW)TableofContents

MODEL 1938 (10KW)

GENERAL INFORMATION

SAFETY RULES

In the Interest of Safety

SafetyPractices

ACCESS TO THE GENERATOR 7

GENERATOR COMPONENTS 8

SYSTEM CONTROLS 9

GENERATOR CLEARANCES I 0

FUEL FACTORS I 0

Power Decreases at Altitude & Temperature 10

STARTING GENERATOR (NO LOAD) 10

Electrical Checks II

AUTOMATIC OPERATION

Sequence of Automatic Events

Utility Fail

Engine Warm-up Time Delay

Utility Voltage Pickup Sensor

Retransfer Time Delay

Engine Cool-down Timer

Testing The Automatic Transfer Switch

GENERATOR AC CONNECTION SYSTEM 12

CHECKING AUTOMATIC OPERATION 13

Stopping The System 13

Generator Load Tests 13

RECONFIGURING THE FUEL SYSTEM 14

SETTING THE EXERCISE TIMER

CIRCUIT INFORMATION

Power During Fault Conditions

Control Module Assembly (CMA)

LED Fault light Conditions

Resetting Fault Detection System

Trickle Charge Operation

FUEL SUPPLY 16

CONTROL MODULE CONNECTORS 17

TRANSFER SWITCH MODULE CONNECTORS 17

TROUBLESHOOTING

TROUBLESHOOTING LED FAULTS 20

Dead Unit /Low Battery Voltage:

(No Blink [ ] /One Blink [ • ]) 20

Check Battery: 20

Check Trickle Charging System: 20

Troubleshoot The Trickle Charging System: 20

Check The Step-down Transformer 21

Low Oil Pressure: (Two Blinks [ • • ]) 22

Low Oil Pressure

Troubleshooting Procedure: 22

Low Voltage: (Three Blinks [° ° • ]) 23

Low Voltage

Troubleshooting Procedure: 23

Engine Fails To Start: (Four Blinks [ .... ]) 24

Troubleshooting Procedure: 24

Engine Cranks But Fails To Start: 25

Gas Regulator 26

Check Ignition Spark: 28

Engine Fails to Crank: 28

Low Frequency: (Five Blinks [ ..... ]) 29

Low Frequency Troubleshooting

Procedure: 29

Over Speed: (Six Blinks [ ...... ]) 3 I

Over Frequency Troubleshooting

Procedure: 31

High Oil Temperature: (Seven Blinks

[....... ]) 32

High Oil Temperature Troubleshooting

Procedure: 32

Service & Troubleshooting Guide - Home Generator Systems

Model 1938 (lOkW) Table of Contents

GENERATOR ASSEMBLY

SPECIFICATIONS 36

Generator 36

Engine 36

ENGINE MAINTENANCE 37

Checking Oil Level 37

Changing Oil & Filter 37

Replacing The Spark Plugs 37

Service The Air Cleaner 38

Inspect Spark Arrester Screen 38

Engine Governed Speed 38

Valve Lash 38

Carburetor Adjustments 38

Engine Adjustment 39

I OKW RESISTANCE VALUES

System Interconnections

10kW Circuit Test Introduction

Checking The Stator Power Winding

Through The Harness

Checking The Battery Charge Winding

(BCW) Through The Harness

Checking The Excitation Circuit

Checking The Stator Power Winding

Checking The Battery Charge

Winding (BCW)

Checking The Rotor Winding

REMOVING THE MECCALTE GENERATOR

Roof Removal 46

Muffler Box Removal 46

Remove Fuel Line From Regulator 47

Alternator Bulkhead Removal 48

Removing The Generator 50

Blind End Cover Removal 50

Generator Isolation Mounts 50

Removing Stator

Mounting Hardware 50

Removing Rotor Through-Bolt

(Stay Shaft Bolt) 5 I

Removing The Rotor Assembly 52

Inspecting The Rotor Assembly 53

APPENDIX

CMA Schematic

Generator Wiring Diagram

50 Amp Wiring Diagram

200 Amp Wiring Diagram

200 Amp with Main Line Disconnect

Wiring Diagram

Transfer Switch Schematic

Oil Heater

240 Volt Battery Warmer

Service & Troubleshooting Guide - Home Generator Systems _& S_ra_fa.

Model 1938 (10kW) General Information _ _'_

GENERAL INFORMATION

MODEL 1938 (I 0KW)

_& St_a. Service&Troubleshooting Guide - Home Generator Systems

'_°_:_ Model 1938 (10k_)General Information

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Service&TroubleshootingGuideHomeGeneratorSystems

Model1938(10kW)GeneralInformation St_an _

SAFETYRULES

In the Interest of Safety _CAUTION: Indicates a hazard

which, if not avoided might

This manual outlines the construction, result in death or serious

function and servicing procedures of

the Briggs & Stratton Power Products®

Home Standby generator series. It is

structured for use by trained

technicians that are working in and

from a properly equipped shop.

Familiarity with the proper method of

using tools, measuring equipment and

injury.

CAUTION: When used without the 1

alert symbol, indicates a situation that

could result in damage to equipment.

NOTE: This notation is used

to inform you of a method,

workshop procedures are essential to reference or procedure that

performing successful maintenance and could assist with specific

repair on this equipment. operations or decisions.

Ensure that all specified tools and/or

equipment are available before [ u^7^Dr_ CVMm_,€ ^_r_ M=^_,_.€ ]

attempting to service this equipment.

For a detailed discussion of the

fundamental principles involved with

the physicsof electrical power

generation, refer to the Familiarization

and Troubleshooting Guide

(Publication #86262 Revision 3 or

later). This manual is available through

your Briggs & Stratton Central

Distributor.

Toxic Fumes Electrocution Explosion

Hot Surface Chemical Burns Fire

Safety Alert Symbols

The safety alert symbol (_) is used

to identify safety information about

hazards that can result in personal

injury. A signal word (DANGER,

WARNING, CAUTION) is used

with the alert symbol to indicate the

Read ExplosivePressure Goggles

Kick Back Disconnect Entanglement

potential severity of injury. In addition,

a hazard symbol may be used to

represent the type of hazard.

_ANGER: 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.

Spark Plug

,_ DANGER

•National electric code requires

generator to be properly grounded to

an approved earth ground. Call an

electrician for local grounding

requirements.

,_ DANGER

•When usinggenerator for backup

power, notify utility company. Use

approved transfer equipment to isolate

generator from electric utility.

•Use a ground fault circuit interrupter

(GFCI) in any damp or highly

conductive area, such as metal decking

or steel work.

•Do not touch bare wires or

receptacles.

• Do not use generator with electrical

cords which are worn, frayed, bare or

otherwise damaged.

•Do not handle generator or electrical

cords while standing in water, while

barefoot, or while hands or feet are

wet.

•Do not allow unqualified persons or

children to operate or service

generator,

_E WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects,

or other reproductive harm.

,_ DANGER

_&St_on Service & Troubleshooting Guide ' Home Generator Systems

'_ Model 1938 (I OkW) General Information

Safety Practices

_k DANGER

,Donot allow any open flame, spark,

heat, or !it cigarette around battery

during, and for several m!nutes after

charging.

,Wea r protective goggles, rubber

apron, and rubber gloves.

_WARNING

•This generator does not meet U.S.

Coast Guard Regulation 33CFR-183 and

should not be used on marine

applications.

• Failureto use the appropriate U.S.

Coast Guard approved generator could

result in bodily injuryand/or property

damage.

•Do not attempt to modify the _/f

I_ unit or use it for any application

it was not designed for. If you

have any questions about your

generator's application, ask your

dealer or consult the factory.

Read these procedures carefully

and become familiar with your

generator set. Know its

applications, its limitations and

any hazards involved.

Never handle any kind of

electrical cord or device while

standing in water, while

barefoot, or while hands or feet

are wet.

•Do not use worn, bare, frayed

or otherwise damaged electrical

cord sets with any generator

set. Using a defective cord may

result in an electrical shock or

damage to the test equipment

and/or the unit.

These units require an adequate

flow of cooling air for their

continued proper operation.

Never operate or service any

unit while inside any enclosure

where the free flow of cooling

air into and out of the unit

might be obstructed. Without

sufficient cooling airflow, the

units quickly overheat, damaging

the generator and/or nearby

property.

Home Standby generators

produce a high voltage that can

cause an extremely dangerous

electrical shock. Avoid contact

with bare wires, terminals, etc.

Never permit an untrained

person to service or assist with

the procedures discussed in this

guide.

Never start or stop a unit with

electrical loads connected to

receptacles and with the

connected loads turned ON.

Start the engine and let it

stabilize before connecting any

electrical loads. Turn OFF and

disconnect all electrical loads

before shutting down any

generator.

• The manufacturer could not

IILLJII possibly anticipate every

circumstance that might involve

a hazard. For that reason,

warnings in manuals and

warnings on tags or decals

affixed to the units are not all-

inclusive. Do not handle,

operate or service a unit with a

procedure or method not

specifically recommended by the

manufacturer.

• This entire book is filled with

,_T-E important safety information

-please read it carefully.

Service&TroubleshootingGuide- HomeGeneratorSystems

Model1938(lOkW)GeneralInformation St_an_

ACCESSTO THEGENERATOR

The Home Generator System is equipped with an enclosure

that has four access doors (Figure I). The doors are named

for the significant component located behind them. Starting

with the side that has the fuel connection and proceeding

clockwise, the doors are named:

OIL SERVICE DOOR

AIR INTAKE DOOR

CONTROL PANEL DOOR

BATTERY DOOR

Each Home Generator System is equipped with three

identical keys. These keys fit the locks that secure the oil

service and control panel doors.

C:AUTiONi Do not operatethe

backup generator unlessthe OIL [

SERVICEand/or CONTROL PANEL I

doors are insta!led. Failure t ° doso wi!! ]

causeoverheating. ]

To remove an access door:

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

to remove and turn one quarter turn clockwise.

NOTE: The key is retained in the lock when the

locks are open.

• Grasp the door's lift handle and pull the door upwards

until the security pins are free of the lower base.

• With the security pins free, pull the lift handle outward

(away) from the unit while pulling the door down and

out of the upper door channel. The door will come

free of the generator enclosure.

The AIR INTAKE DOOR does not have locks or lift

handles. You must remove a locking screw found directly

above the center of the door. They are removed in the

same way the locking doors are removed. To secure these

access doors, replace the locking screws.

WARNING

burns.

To install an access door:

• Support the door by grasping the lift handle or louver.

Guide the top of the door into the generator

enclosure.

•Lift the door up into its upper channel until the security

pins clear the sill of the enclosure.

• Push the lower half of the door into the door recess

until it is flush with the sides.

• Seat the door by pushing it down until the rubber

coated security pins engage and the door rests on the

mounting sill.

• When installing a Iockable door, turn the key one

quarter turn counterclockwise and remove the key.

_& Stra_on Service & Troubleshooting Guide ' Home Generator Systems

'_ Model 1938 (I OkVV) General Information

GENERATOR COMPONENTS

Air Cleaner m Uses a dry type filter element and foam Exhaust Port m High,performance muffler lowers engine

precleaner to prevent dirt and dust from being drawn into noise to comply with most residential codes.

the engine, Oil DipStick--Used to check the engine oil level.

Battery--12 VDC, 33 Amp-Hour sealed battery provides" Oil Drain Hose m Provided to facilitate changing oil.

Control Panel Used for various test, operation and

PANEL on the next page. Unit Data Decal m Identifies unit by serial number,

Service&TroubleshootingGuide- HomeGeneratorSystems

Model1938(lOkW)GeneralInformation St_an_

SYSTEH CONTROLS

I 5 Amp Fuse -- Protects the Home Generator System •OFF position turns off running generator, takes system

DC control circuits. If the fuse has blown (melted open) or out of Automatic mode and resets any detected faults.

was removed, the engine cannot crank or start. Replace the • MANUAL position starts the engine but does not

fuse using only an identical BUSSAGC 15A fuse. disconnect from utility power. It is used for

AUTO/OFF/MANUAL Switch -- This three-position maintenance or diagnostic functions.

device 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 and the

internal engine temperatures stabilize, it shuts off the

generator, and waits for the next utility power outage.

Circuit Breaker Protects the system from shorts and

other over-current conditions. Must be ON to supply

power to the Automatic Transfer Switch.

Diagnostic LED Used for troubleshooting operational

problems with the Home Generator System. All fault

conditions are described in the section LED Fault Light

Conditions.

While waiting, it maintains the battery with a trickle

charge. Hour Meter The hour meter records the total number

of hours the generator has been running and is used to

schedule maintenance tasks.

Set Exercise Switch -- Used to set the exercise cycle

start time and day-of-the-week. Exercise cycle only occurs

in AUTO mode.

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