Home Generator System Manual GS Rev A 6/08. BRIGGS & STRATTON SERVICE & TROUBLESHOOTING MANUAL HOME GENERATOR SYSTEM - 30kW

Transcription

1 Home Generator System Manual GS Rev A 6/08 BRIGGS & STRATTON SERVICE & TROUBLESHOOTING MANUAL HOME GENERATOR SYSTEM - 30kW

2 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. Copyright 2008 Briggs & Stratton Corporation All rights reserved. No part of this material may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying or recording by any information storage and retrieval system, without prior written permission from Briggs & Stratton Corporation.

3 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 FUEL SUPPLY ENGINE MAINTENANCE SETTING THE EXERCISE TIMER SECTION 2 - TROUBLESHOOTING...17 SYSTEM CONTROL PANEL (SCP) FAULT CODE INDICATIONS STOPPING THE SYSTEM FOR MAINTENANCE GENERATOR AC CONNECTION SYSTEM (FAULT CODE_1) DEAD UNIT/LOW BATTERY VOLTAGE (FAULT CODE_2) LOW OIL PRESSURE (FAULT CODE_3) LOW OUTPUT VOLTAGE (FAULT CODE_4) ENGINE FAILS TO START/FAILS TO CRANK (FAULT CODE_5) UNDER FREQUENCY (FAULT CODE_6) OVER FREQUENCY (FAULT CODE_7) HIGH TEMPERATURE (FAULT CODE_8) TRANSFER SWITCH FAILURE Page i

4 SECTION 3- SPECIFICATIONS & REFERENCE...59 SPECIFICATIONS SCHEMATIC WIRING DIAGRAM Page ii

5 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. WARNING Before attempting to service this equipment, read and understand this manual and the operating instructions of the equipment 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. HAZARD SYMBOLS AND MEANINGS 1 Failure to follow instructions could result in DEATH, SERIOUS INJURY (including paralysis) or property damage. 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. Explosion Toxic Fumes Fire Rotating Parts Electrical Shock Hot Surface 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. Auto Start Explosive Pressure Chemical Burn Lift Hazard Read Manual CAUTION: When this signal word is used without the alert symbol, it indicates a situation that could result in damage to the engine. 1

6 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 monoxide, 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 monoxide alarm near the bedrooms. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or other openings. WARNING Generator produces hazardous voltage. 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 barefoot, or while hands or feet are wet. If you must work around a unit while it is operating, stand on an insulated dry surface to reduce shock hazard. DO NOT allow unqualified persons or children to operate or service generator. In case of an accident caused by electrical 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 generator, operating this equipment imprudently, 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 equipment 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 working on the equipment. 2

7 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 conditions 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 combustibles 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 protective 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 frequency and voltage when running at governed 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. 1 3

8 1 CAUTION Exceeding generators wattage/amperage capacity can damage generator and/or electrical 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 generator 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 generator, operating this equipment imprudently, 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. 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 allinclusive. Do not handle, operate, or service the unit using a procedure or method that is not specifically recommended by the manufacturer. 4

9 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 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. 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. 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. 1 Figure1 5

10 GENERATOR COMPONENTS 1 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 constant 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 system life. G - Oil Drain Plug - Provided to facilitate oil changing. H - Ignition Coil - Amplifies the voltage of electricity supplied to the ignition system. J - Battery Negative Cable - Cable connects negative battery terminal to various electrical circuit 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 pressure. L - Starter Contactor/Motor - The starter contactor supplies the high current needed to run the starter motor and also provided 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 circuit 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 connection. U - Automatic Voltage Regulator - Access hole for voltage regulator adjustment. V - Control Panel - Used for various tests, operation, and maintenance functions. See System Control Panel on the next page. 6

11 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). 7

12 1 NOTE: Generator is shown with access door removed. A - Over Temperature Switch - Switch for automatically 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 (voltage pulse) is generated. The engine control unit uses this to monitor engine speed to maintain a specific generator frequency. 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. Connected to utility power and fully automatic. C - Air Cleaner - Protects engine by filtering dust and debris out of intake air. 8

13 GENERATOR CLEARANCES WARNING Running engine gives off carbon monoxide, 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 monoxide alarm near the bedrooms. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or other openings. 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. 1 WARNING Exhaust heat/gases can ignite combustibles 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. 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 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. 9

14 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: 1 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. 10

15 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. 1 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. 11

16 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%. 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. 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 conditions 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 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. 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 12

17 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 nonsynthetic 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). 1 Figure2 13

18 Changing Engine Oil CAUTION 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. 1 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. 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. NOTICE Any attempt to crank or start the engine before it has been properly serviced with the recommended 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 failure to follow this instruction will void engine and generator warranty. 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. 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 (-)). 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 failure to follow this instruction will void warranty. 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. 14

19 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. 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. 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. 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 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 cooling slots. 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 Set generator s system switch to AUTO. 9. Reset exercise timer. See Setting Exercise Timer. 15

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21 SECTION 2 - TROUBLESHOOTING SYSTEM CONTROL PANEL(SCP) The System Control Panel (SCP) 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. The system control panel interprets and monitors electrical inputs from related circuits throughout the standby installation. Before replacing the system control panel, all other circuits must be tested to ensure proper operation. When a failure has been traced to the system control panel, the board must be replaced as a complete assembly. Functions of the System Control Panel: Battery Trickle Charge Set Exercise Timer (SET EXERCISE) Manual Start (MANUAL OVER-RIDE) Sensing Utility Voltage Automatic Start, in event of utility failure Automatic Engine Cool-Down Timer Fault Code Detection with Automatic Shutdown Fault Indication Display (LED) Diagnostic Access Port (SERVICE TOOL) Hour Meter Power During SCP Fault Conditions How to ACCESS the System Control Panel The system control panel is mounted behind the face of the control panel (Figure 1,A). 1. Remove the control panel door. Figure 1 2. Make sure the SYSTEM switch is set to OFF. 3. Remove the 15 AMP fuse from the system control panel. 4. Disconnect the negative (-) battery cable. 5. Disconnect 10-pin connectors from the edge of the system control panel board. 6. Remove the four mounting screws (Figure 2, A) that secure the face of the control panel, then carefully remove and tilt down the panel to expose the board. 2 When the Home Generator System experiences a fault condition, the automatic transfer switch automatically defaults to UTILITY POWER.This ensures that utility power is available to all circuits in the home until the fault is corrected. If the unit fails to exercise at its prescribed time, check for a fault code on the generator control panel display. If no fault code is shown, perform the SET EXERCISE procedure. Figure 2 The system control panel is connected to its various circuits through three connectors that are mounted directly to the board (Figure 3), shown tilted down. 17

22 2 The 8-pin connector (A) is wired to the internal systems of the unit and is the primary point of measurement for troubleshooting. The connector supplies 240VAC from UTILITY power. The 10- pin connector (B) is used for optional generator features. In addition, the system control panel also has connections for L1 and L2 (C), which sense 240VAC on the generator, and four terminals (D), which are used for optimal battery and engine warmers. The functions of the 8-pin connector is shown in (Figure 5). Pin Pin Pin Pin Pin Pin Pin Pin Figure Vacant Vacant Oil Pressure (Wire #85) Oil Temperature (Wire #95) Fuel Solenoid (Wire #14) Start Circuit (Wire #56) Ground (Wire #0) Battery Trickle Charge (Wire #13) Figure 3 FAULT CODE INDICATIONS The system control panel is equipped with sensing circuits that automatically shut down the generator in the event of potentially damaging conditions. To show probe locations for troubleshooting with a test meter, an arrow from a connector/pin illustration will be shown against the exposed system control panel board (Figure 4). Note that the board will be shown upside down in relation to the actual schematic in the manual A digital display on the face of the control panel will show the type of failure (FAULT CODE) that has occurred. An optional LED indicator can be mounted elsewhere in the system to provide a remote indication of generator failures. When the system control panel senses a condition that prevents the generator from functioning properly, it shuts down the generator and displays the fault code on the control panel. At the same time, it signals the remote LED to flash in a sequence that corresponds to the fault code. Figure 4 18

23 For example, FC_1 (Fault Code) on the control panel display indicates Low Battery Voltage and the remote LED would repeatedly flash once with a pause until it s reset or the condition is corrected. FC_2 Low Oil Pressure would cause the remote LED to repeatedly flash twice and pause. Following is a list of the possible fault codes. (FC_1) Low Battery Voltage (FC_2) Low Oil Pressure (FC_3) Low Output Voltage (FC_4) Engine Fails To Start (FC_5) Low Frequency (FC_6) Engine Overspeed (FC_7) High Temperature (FC_8) Transfer Switch Failure Resetting the Fault Code Detection System After correcting the failure indicated by the fault code, the operator or technician must reset the fault detection system before the Home Standby System will operate. 1. Place the SYSTEM switch in the OFF position for 5 seconds or more. 2. Place the SYSTEM switch in the AUTO position. STOPPING THE SYSTEM FOR MAINTENANCE WARNING Turn switch to OFF. Remove 15 Amp fuse from the system control panel. Disconnect spark plug wire from plug. This will prevent accidental starts. 1. Ensure the main line disconnect (MLD) is ON and power is supplied to the UTILITY CONNECTION lugs of the transfer switch. 2. Set the generator SYSTEM to OFF. 3. Set the generator main circuit breaker to OFF. 4. Remove the 15 Amp fuse from the system control panel. NOTE: Exercise timer will need to be reset whenever the control panel fuse is removed. SEE RESETTING THE EXERCISE TIMER ON PAGE If the fault code is not corrected, the unit will return to Auto Shutdown and the same fault code indication(s) will be displayed. 19

24 GENERATOR AC CONNECTION SYSTEM 2 A single-phase, three-wire AC connection 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 junction of leads L2 & L3 forms the neutral lead, as shown schematically and as wiring diagram (Figure 6). A complete schematic and wiring diagram can be found later in this manual. NOTE: Neutral is not bonded to ground at generator. Figure 6 20

25 FC_1 DEAD UNIT/LOW BATTERY VOLTAGE 2 Figure 7 21

26 2 (FC_1) DEAD UNIT/LOW BATTERY VOLTAGE If the generator cannot start because the battery output power is below that needed to crank the engine, the digital display will show FC_1 and the remote LED will repeatedly flash once with a pause. NOTE: A completely discharged battery will not be capable of powering any of these displays. The causes for a low or discharged battery may be: Blown Automatic Transfer Switch Fuse(s) Blown fuse(s) in circuit breaker panel Blown system control panel fuse Blown battery fuse Blown ECU fuse Failed system control panel trickle charger Failed battery WARNING Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Parasitic drain on battery The circuit functions and test/repair procedures for these conditions are outlined below. SEE SCHEMATIC ON PAGE 60 FOR CIRCUIT DETAILS. WARNING Utility voltage is present at the system control panel board. Use caution to avoid personal electrical shock or damage to the system. NOTE: The trickle charge circuit is a float charger type. 240VAC UTILITY is delivered from the fuses in the transfer switch to the fuses in the generator circuit breaker panel. From there it flows to the 2 spade connectors mounted directly on the system control panel board. The system control panel uses internal circuits to rectify this UTILITY voltage to 12VDC. It is then delivered to the (+) battery post through the 15 Amp fuse on the system control panel via Pin #1, Wire #15A, 20 Amp Engine Control Unit (ECU) fuse and the 50 Amp battery fuse. When UTILITY voltage is present and the unit is switched to the AUTO or OFF position, the trickle charge circuit in the system control panel will maintain the voltage of a fully charged battery. The trickle is not capable of charging a dead battery. TEST 1 - Check Battery 1. Set SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Disconnect battery cables, negative (-) first. 4. Using the approved procedure for your battery tester, check the battery state-ofcharge. If the battery is discharged, connect to an appropriate battery charger. Charge the battery in accordance to the battery manufacturer instructions. If the battery replacement is required, the replacement must be the same 12VDC, with an Amp rating specified in the unit installation or operator manual. 5. Connect the battery cables, positive (+) first. 6. Reinstall the 15 Amp fuse in the system control panel. 7. Set SYSTEM switch to AUTO, then push and hold MANUAL OVER-RIDE to start the unit. 8. Reset the exercise timer. TEST 2- Check Trickle Charge Voltage at Battery NOTE: The trickle charge system will not operate if the battery voltage is below 10VDC. To test the 22

27 trickle charge output, a fully charged battery must be installed in order to turn the trickle charge on. 1. Set SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system contol panel. 3. Inspect the fuse to see if blown. If fuse is good, proceed to Step 4. A blown fuse indicates a short in the circuit. Repair any short and replace fuse before proceeding to Step Disconnect the negative (-) battery cable. 5. Disconnect the positive (+) battery cable from the starter motor. 6. Isolate Wire #13 (small wire) from the positive (+) battery cable (Figure 8).Do not allow Wire #13 to touch ground. 2 Figure 9 Figure 8 7. Reconnect negative (-) battery cable to negative battery terminal. 8. Ensure UTILITY voltage is turned ON. 9. Reinstall 15 Amp control panel fuse. 10. Set the meter to measure DC voltage. Connect positive (+) meter test lead to Wire #13. Connect negative (-) meter test lead to negative (-) battery terminal. 11. While observing the meter and keeping the positive (+) meter test lead connected to Wire #13, momentarily touch Wire #13 and meter test lead to the positive (+) battery cable, then remove (Figure 9). This will turn on the trickle charger long enough to read the trickle charge output voltage on the meter. 12. About 13.5 VDC should be measured when the wire is removed from the post. The trickle charge voltage will diminish quickly. If no voltage is measured, proceed to TEST 3 - Check 50 Amp Battery Fuse. If voltage is measured, the trickle charger is functioning. Reconnect all wiring, return the unit to standby mode and reset the exercise timer. 23

28 Test 3 - Check 50 Amp Battery Fuse WARNING Utility voltage is present at the system contol panel board. Use caution to avoid personal electrical shock or damage to the system Inspect the 50 Amp fuse in Wire #13 located close to the starter motor (Figure 10,A). Figure 11 Figure 10 If the fuse is good, proceed to TEST 4 - Check Trickle Charge Voltage at Pin #1. A blown fuse indicates a short in the circuit. Inspect the circuit and repair any shorts. Replace fuse. TEST 4 - Check Trickle Charge Voltage at Pin #1. 1. Ensure UTILITY power is turned ON to the transfer switch. 2. Set SYSTEM switch to OFF. 3. Remove the 15 Amp fuse from the system control panel. 4. Make sure Wire #13 is reinstalled to the positive (+) battery cable at the starter motor and the 50 Amp fuse is installed in Wire # Gain access to the control panel. SEE HOW TO ACCESS THE CONTROL PANEL ON PAGE Set meter to measure DC Voltage. Connect positive (+) meter test lead to Pin #1, Wire #13 (Figure 11). 7. Connect negative (-) meter test lead to negative (-) battery terminal. If battery voltage is measured, proceed to Step 8. If no battery voltage is measured, proceed to TEST 8 - Check ECU Fuse. 8. Reinstall the 15 Amp fuse in the system control panel. After a few seconds, meter should measure trickle charge voltage around 13.5 VDC. 9. While observing the meter and keeping the positive (+) meter test lead connected to Pin #1, Wire #13, remove the 50 Amp battery fuse in Wire #13, located near the starter motor. The trickle charger will stay on long enough to read the trickle charge output voltage on the meter, but trickle charge voltage will diminish quickly. If 13.5 VDC is measured at Pin #1, Wire #13, but not at the positive (+) battery connection, proceed to TEST 5 - Check 240 VAC Across Wire #92 & #93. If no voltage in measured at Pin #1, Wire #13, proceed to TEST 8 - Check ECU Fuse. TEST 5 - Check 240 VAC Across Wire #92 and Wire # Remove the 15 Amp fuse from the system control panel. 2. Gain access to the system control panel. 3. Verify Utility Voltage is ON. SEE HOW TO ACCESS THE SYSTEM CONTROL PANEL ON PAGE

29 4. Set meter to measure AC Voltage. Connect test leads across Wires #92 and # VAC Utility should be measured (Figure 12). 2 Figure 12 If no voltage is measured, proceed to TEST 6. If 240 VAC UTILITY is measured, verify no trickle charge output is present as described in TEST 4 - Check Trickle Charge Voltage at Pin #1. If no trickle charge voltage is measured, but 240 VAC Utility is present at Wires #92 and #93, replace the system control panel. Figure Check the two fuses located inside the circuit breaker box (Figure 14, A). WARNING Utility voltage is present at the system contol panel board. Use caution to avoid personal electrical shock or damage to the system. TEST 6 - Check for 240VAC at 10 Amp Fuse Inside Circuit Breaker Panel. 1. Make sure Utility power is turned OFF to home generator system. 2. Set SYSTEM switch to OFF. 3. Remove the 15 Amp system control panel fuse. 4. Remove the circuit breaker cover (Figure 13). Figure 14 A blown fuse indicates a shorted circuit. Repair any shorts and replace fuse. If fuse is okay, continue with Step Ensure the Utility power is turned ON to the system control panel. 7. Set meter to measure AC Voltage. 8. Check for Utility voltage across the two wires coming from Utility power. 240 VAC Utility should be measured. 25

30 If 240 VAC Utility voltage is present at the fuse connections, but not at the sytem control panel, repair any wiring between the fuses and the system control panel. If no voltage is present, proceed to TEST 7 - Check for 240 VAC at 10 Amp fuse inside Automatic Transfer Switch. replace wiring between Utility power and the fuse holder. TEST 8 - Check ECU Fuse. 1. Turn the SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Remove the system control panel cover to gain access (Figure 16). 2 TEST 7 - Check for 240 VAC at 10 Amp Fuse Inside Automatic Transfer Switch. 1. Gain access to the Automatic Transfer Switch. 2. Check the two fuses located inside the Automatic Transfer Switch. A blown fuse indicates a shorted circuit. Repair any shorts and replace fuse. If fuses are okay, proceed with Step Make sure Utility voltage is turned ON. 4. Measure for Utility voltage across wires on the load side of the fuses, going to the standby generator (Figure 15). Figure Locate and inspect the 20 Amp ECU fuse (Figure 17,A). Figure 15 If 240 VAC Utility is present at the fuses in the transfer switch, but no voltage is present at the fuses in the generator, there is an open circuit between the generator and the Automatic Transfer Switch. Repair/replace any defective wiring and proceed to TEST 2 - Check Engine Oil Pressure. If no voltage is present at the fuses in the Automatic Transfer Switch, repair/ Figure 17 A blown fuse indicates a short in the circuit. Because this fuse primarily protects the ECU and it s functions, a blown fuse would likely be related to something in the ECU or throttle control. Repair or replace any shorts and replace the fuse, then proceed to TEST 2 - Check Engine Oil Pressure. If the fuse is good, proceed to Step Set meter to measure DC Voltage. 26

31 6. Measure for 12 VDC at fuse on load side, Wire #15A (Figure 18). 2 Figure 18 If voltage is present at the fuse but not present at Pin #1, Wire #15A on the CMA, repair/replace wiring between the 50 Amp fuse and the ECU fuse. If no voltage is present, repair/replace wiring between 50 Amp battery fuse (Figure 10,A) and ECU fuse. 7. After repair, proceed to TEST 2 -Check Engine Oil Pressure. 27

32 2 28

33 FC_2 LOW OIL PRESSURE 2 Figure 19 29

34 2 (FC_2) LOW OIL PRESSURE WARNING Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. The standby generator is equipped with a Low Oil Pressure (LOP) switch. The contacts of the switch are normally closed, but are held open by engine oil pressure during operation. Should the engine oil pressure drop below a predetermined level, the contact will close. This completes a circuit to ground Wire #85 and the system control panel shuts the engine down. The digital display will show FC_2 and the remote LED will repeatedly flash twice with a pause. During cranking and immediately after engine start, the following occur: The system control panel bypasses the LOP switch for several seconds during the initial cranking. The LOP switch opens when engine produces sufficient oil pressure. The system control panel senses that the engine is running by monitoring voltage on Wires #L1 and #L2. After the system control panel senses that the engine is running, it looks for a ground on Wire #85. If Wire #85 is grounded, the system control panel shuts the engine down and displays FC_2. Refer to Figure 19 for troubleshooting flow. Correcting Low Oil Pressure 1. Fix any obvious oil leaks and, if necessary, add the recommended oil to the FULL mark on the dipstick. 2. Reset the fault code detection system. SEE RESETTING THE FAULT CODE DETECTION SYSTEM ON PAGE Start the generator and listen for any abnormal sounds that might indicate engine damage from low oil. SEE TESTING MANUAL OPERATION (NO LOAD) ON PAGE 52. If a low oil pressure condition still exists, the engine will shut down after approximately 10 seconds and the control panel will again display FC_2. Proceed to TEST 1 - Measure for Short-To-Ground. TEST 1 - Measure for Short-To-Ground 1. Set the SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Turn off Utility voltage to the standby generator. 4. Remove the control panel cover to gain access to the system control panel. SEE HOW TO ACCESS THE SCP ON PAGE Remove the the 8-pin connector from the system control panel (Fig. 20). Figure Measure for short-to-ground on Wire #85 (Figure 21). 30

35 Figure 21 If no short is detected, proceed to TEST 2 - Check Engine Oil Pressure. If short is detected, continue with Steps Repair and/or replace wiring, as necessary, then retest. 8. Reconnect Wire #85 to the LOP switch. 9. Reconnect the 8-pin connector to the system control panel. 10. Reinstall the control panel cover. 11. Reinstall the 15 Amp fuse in the system control panel. 12. Set the SYSTEM to AUTO, then push and hold MANUAL OVER-RIDE to start the unit. TEST 3 - Check Oil Pressure Switch 1. If it is not already, install the LOP switch. 2. Turn the SYSTEM switch to AUTO. Push and hold the MANUAL OVER-RIDE switch to start the engine. 3. With the engine running, check the switch with a continuity tester The switch contacts should be open (no continuity). If the switch is OK, replace the system control panel, and proceed to Step 4. If the switch is defective, replace it and continue with Steps Reset the fault code detection system. SEE RESETTING THE FAULT CODE SYSTEM ON PAGE Start the generator and verify FC_2 does not occur. 6. Set SYSTEM switch to OFF. 7. Turn UTILITY ON (if turned off). 8. Return SYSTEM switch to AUTO. 9. Reset the Exercise Timer. SEE SETTING THE EXERCISE TIMER ON PAGE TEST 2 - Check Engine Oil Pressure Contact Power Solutions, Inc (PSI Technical Service Specialists: or at: Servce@PowerGreatLakes.com) for specifications, testing, and troubleshooting engine oil pressure. If oil pressure is normal, proceed to TEST 3 - Check Oil Pressure Switch. If oil pressure is low, contact engine manufacturer for engine troubleshooting procedure. 31

36 2 32

37 2 Figure 22 33

38 2 (FC_3) LOW OUTPUT VOLTAGE The low voltage shutdown feature is designed to protect the generator and its loads from an output voltage that is too low. When the generator has stabalized, the system control panel senses output voltage on Pins #J8 and #J9 and on Wires #L1 and #L2. SEE WIRING DIAGRAM ON PAGE 61. If the system contol panel does not sense the proper generator voltage, it will shut down the unit. The digital display will show FC_3 and the remote LED will repeatedly flash three times with a pause. Low output voltage may be caused by: An open control panel circuit breaker A generator that is overloaded A restriction in the fuel flow A broken or disconnected signal lead (L1 or L2) Diminished engine power A failed alternator winding Open wiring TEST 1 - Measure Circuit Breaker Load-Side Voltage 1. Remove the cover from the generator circuit breaker. SEE TESTING MANUAL OPERATION (NO LOAD) ON PAGE Reset the fault code detection system. SEE RESETTING THE FAULT CODE DETECTION SYSTEM Ensure that the generator circuit breaker is ON and the 15 Amp control panel fuse is installed. 4. Turn the SYSTEM switch to AUTO, then push and hold the MANUAL OVER-RIDE button to start the generator. 5. When the unit has stabalized, check for 240VAC at the load side of the circuit breaker (Figure 23). WARNING Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Figure 23 If the specified voltage is present, proceed to TEST 2 - Measure Generator Voltage at System Control Panel. If specified voltage is not present, proceed to TEST 3 - Measure Circuit Breaker Line-Side Voltage. WARNING Utility voltage is present at the system control panel board. Use caution to avoid personal electrical shock or damage to the system. TEST 2 - Measure Generator Voltage at System Control Panel 1. Remove control panel cover to gain access to the system control panel. SEE HOW TO ACCESS THE SYSTEM CONTROL PANEL ON PAGE With the unit running, measure for 240VAC at system control panel Pins J8 and J9 and Wires # L1 and L2 (Figure 24). 34

39 2. Remove the 15 Amp system control panel fuse. 3. Gain access to the Automatic Voltage Regulator (AVR). Position control panel assembly and secure secure with tie straps as needed. (Figure 25). Figure 24 If no voltage is present: A. Ensure the circut breaker is ON. B. Repair or replace the wires between the circuit breaker and L1 and L2. C. Restest for 240VAC. If 240VAC is present, replace the system control panel board. TEST 3 - Measure Circuit Breaker Line-Side Voltage 1. Ensure the circuit breaker is ON. 2. Start the generator and measure for 240VAC on the line-side of circuit breaker. If there is no voltage on the line-side of the breaker, proceed to TEST 4 - Bypass the Automatic Voltage Regulator. If there is voltage on the line-side of the breaker, but none on the load-side, manually cycle the circuit breaker and retest. If there is still no voltage on the load-side, replace the circuit breaker. NOTE: For complete alternator technical support contact Marathon Electric Generators at: 100 E. Randolf Street, PO Box 8003,Wausau, Wisconsin, , or at , or at TEST 4 - Bypass the Automatic Voltage Regulator (AVR) NOTE: The generator No Load voltage is dependent on exciter input voltage and generator speed. With the generator operating at rated speed and 12 VDC applied to the exciter field, the generator s terminal voltage will be near rated value. 1. Set SYSTEM swith to OFF. Figure Disconnect the positive (F+) and negative (F-) AVR leads and while observing correct polarity, connect them to a 12V battery. 5. Reinstall the 15 Amp control panel fuse. 6. Turn the SYSTEM switch to AUTO, then push and hold the MANUAL OVER-RIDE button to start the generator. 7. Measure the terminal voltage, and compare with rated voltage (Figure 26). Figure 26 If the specified voltage is present, replace the automatic voltage regulator. If the specified voltage is not present, proceed to TEST 5 - Test Alternator Windings. 2 35

40 2 TEST 5 - Test Alternator Windings There are four components that contain windings that form an electrical path of low resistance. Each component can be checked for continuity. To Check Winding for Continuity: 1. Using meter, measure the loop resistance of the following four components: Exciter Stator Exciter Rotor Main Stator Main Rotor 2. Verify measured values against those listed in the table below. NOTE: These very small resistances require precision test equipment to obtain accurate measurements. However, a standard meter will provide a good indication of winding continuity. Figure 28 Generator Rotor Resistance Generator Resistance Exciter Field No Exciter Resistance Stator Rotor Load Volts Stator Rotor Figure 29 Exciter Stator Resistance Figure 27 Generator Stator Resistance Figure 30 Exciter Rotor Resistance If winding resistance is acceptable,proceed to Insulation Resistance Test. If winding resistance is not acceptable, repair or replace as necessary. 36

41 Insulation Resistance Test This test measures the quality of the insulation materials that keep the electrical windings and the generator s steel core seperated. Dust, dirt, and moisture can cause the insulation to erode over time. Most winding failures are due to a failure in the insulation system. Winding insulation can be checked on the main stator and rotor and on the exciter stator and rotor. 1. Set SYSTEM switch to OFF. 2. Remove the 15 Amp system control panel fuse and disconnect the negative (-) battery cable. 3. Remove all regulators, diodes, surge protectors, capacitors and relays from the winding circuit before testing. 4. Using a mega-ohm meter, check for a minimum insulation resistance of 2 megaohms. If insulation resistance is acceptable, proceed to Diode Test. If insulation resistance is not acceptable, repair or replace as necessary. Diode Test NOTE: To access diodes, the engine must be rolled over. Contact engine manufacturer for instructions on how to roll over engine. 1. Remove the 2 main rotor leads from the rectifier assembly. 2. Remove the 3 exciter rotor leads fro the rectifier assembly. The diodes and the diode test leads will remain mounted to the posts during the testing process. 3. Using meter set to measure Ohms (Ω), place one test lead on the diode lead terminal post. 4. At the same time, touch the other test lead to the diode mounting nut (Figure 31). Figure Reverse the test lead probes and repeat Steps 3 and 4 (Figure 32). Figure Using Steps 3-5, test the six diodes in the forward and the reverse directions. If the diode is GOOD, greater resistance will be measured in one direction more than the other. If the diode is SHORTED, the meter will read 0 or, the resistance will be very low in both directions. Replace the rectifier assembly if one or more diodes are SHORTED. If the diode is OPEN, the meter will have an infinity reading in both directions. Replace the rectifier assembly if one or more diodes are OPEN. 2 37

42 2 38

43 2 Figure 33 39

44 2 (FC_4) ENGINE FAILS TO START Whenever the unit is directed to start (MANUAL OVER-RIDE or AUTO), the system control panel delivers 12VDC from Wire #56, Pin #3 to the starter contactor for seconds. It then pauses for seconds and repeats the attempt until 2 minutes of start time have accumulated. During the strarting attempt, the starter control panel also delivers 12VDC from Pin #4, Wire #14 to the 5 Amp fuse. From the fuse, Wire #14A delivers the 12 VDC to both the fuel solenoid and the ECU (Engine Control Unit). From the fuel solenoid, Wire #14B delivers this voltage to Pin #5 on the ECU. The ECU controls the opening of the fuel valve, controlling fuel flow. Wire #14A also delivers 12 VDC to Pin #15 on the ECU. This is considered a key on signal. Pins #22 and #23 on the ECU recieve a signal from the RPM sensor. This signals the ECU that the engine is rotating. When these signals are received, the ECU will ground Wire #56A (Pin #3 on the ECU). This will energize PR (Power Relay) closing it s contacts. When the PR is energized, 12 VDC on Wire #15B is connected to the ignition coil and engine alternator. The system control panel also monitors Wires #L1 and #L2 for a minimum voltage. When the system control panel receives the minimum voltage signal, it recognizes the generator has started and discontinues the voltage signal to the starter contactor. However, if the minimum voltage has not been sensed after approximately 2 minutes of accumlative start time, the system control panel terminates the engine cranking cycle. The digital display will show FC_4 and the remote LED will repeatedly flash four times with a pause. The engine will not start until the FC_4 is cleared. WARNING Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. This fail code directs the service technician to examine systems that could be preventing the unit from operating. For example: No Alternator Output Voltage Circuit Breaker in OFF position No Fuel Blown Fuse Fuel Solenoid Failure Fuel Supply Discrepancies Failed Starter Motor Failed Starter Motor Connections Engine Component Failures Clogged Engine Air Filter Failed Ignition System Failed Battery Fuse Failed ECU Fuse Failed Fuel Solenoid Fuse Failed ECU Failed and/or Damaged Wiring Clogged Atmospheric Vent Troubleshooting Engine Start Failures 1. Reset the fault code detection system. SEE RESETTING THE FAULT CODE DETECTION SYSTEM ON PAGE Set SYSTEM switch to AUTO and push MANUAL OVER-RIDE to start the unit. 3. The engine will do one of the following: The engine will start and stop several times through the 2 minute cycle. If the engine starts and shuts down every seconds for a two minute duration then finally shuts down, and FC_4 is shown on the digital display, the failure is caused by no voltage on Wires L1 & L2 at the system control panel. An OPEN MAIN CIRCUIT breaker could be the cause. Use FC_3 troubleshooting for this condition (Page 34). The engine will crank and fail to start. Use TESTS 1-5 for starting failures. The engine will fail to crank. Use TESTS 1-4 for cranking failures. 40

45 ENGINE FAILED TO START TEST 1 - Check Fuel Solenoid Signal 1. Turn SYSTEM switch to OFF. 2. Remove the 15 fuse from the system control panel. 3. Disconnect Wire #14A from the fuel solenoid. 4. Set meter to measure DC Voltage. Connect positive (+) meter test lead to wire (Figure 34,A). TEST 2 - Check SCP Output WARNING Utility voltage is present at the system control panel board. Use caution to avoid personal electrical shock or damage to the system. 1. Turn SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Gain access to system control panel. SEE HOW TO GAIN ACCESS TO SYSTEM CONTROL PANEL ON PAGE Set meter to measure DC Voltage. Connect positive (+) test lead to Pin #4, Wire #14 (Figure 35). 2 Figure Connect negative (-) meter test lead to battery negative post (Figure 27,B). 6. Reinstall the 15 Amp fuse in the system control panel. 7. Turn SYSTEM switch to AUTO. 8. While observing the meter reading, push and hold the MANUAL OVER-RIDE button. Battery voltage should be measured. If battery voltage is measured, proceed to TEST 3 - Check Ignition Coil Signal. If no voltage is measured, proceed to TEST 2 - Check SCP Output. Figure Connect negative (-) meter test lead to battery ground. 6. Reinstall the 15 Amp fuse in the system control panel. 7. Turn the SYSTEM switch to AUTO. 8. While observing the meter reading, push and hold the MANUAL OVER-RIDE button. Battery Voltage should be measured. If battery voltage is measured, proceed to Step 9. If no voltage is measured and engine cranks but does not start, replace the system control panel. 41

46 9. Turn the SYSTEM switch to OFF. 10. Remove the 15 Amp fuse from the system control panel. 11. Inspect the 5 Amp fuse located in Wire #14 (Figure 36,A). TEST 3 - Check Ignition Coil Signal 1. Turn the SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Unplug the Wire #18 (purple wire) connector from the ignition coil (Figure 37). 2 Figure 36 A blown fuse indicates a shorted circuit. Repair any shorts and replace fuse. If fuse is okay, proceed to Step Connect the positive (+) meter test lead to the load side of the 5 Amp fuse, next to Wire #14A. Connect negative (-) test lead to the negative (-) battery terminal (Figure 27). 13. Reinstall the 15 Amp fuse in the system control panel. 14. Turn SYSTEM switch to AUTO. 15. While observing the meter, push and hold the MANUAL OVER-RIDE button. Battery voltage should be measured. If battery voltage is measured at the load side of the fuse, repair/replace wiring between 5 Amp fuse and fuel solenoid, Wire #14A. If no voltage is measured, repair/ replace wiring between 5 Amp fuse and system control panel. Figure Set meter to read DC Voltage. 5. Insert the positive (+) meter test lead to Wire # Insert the negative (-) meter test lead to the battery negative terminal. 7. Reinstall the 15 Amp fuse in the system control panel. 8. While obseving the meter, push and hold the MANUAL OVER-RIDE button. Battery voltage should be measured. If battery voltage is measured, the CMA and the ECU control logic are functioning normally. Proceed to TEST 4 - Check Fuel Supply Pressure. If no battery voltage is measured, proceed to TEST 5 - Check ECU Inputs. 42

47 TEST 4 - Check Fuel Supply Pressure 1. Install Briggs & Stratton manometer #19495 as illustrated in (Figure 38) to verify that fuel pressure is available to the fuel solenoid. LP or NG fuel supply pressure should be 7 to 11 inches of water (in W.C.) at full load with all gas appliances turned on and operating. To Test ECU Inputs: 1. Turn the SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Gain access to the system control panel. SEE HOW TO ACCESS SYSTEM CONTOL PANEL ON PAGE Disconnect the wiring harness from the ECU. 5. Set the meter to measure continuity. Insert one test lead in Pin #10, Wire #0 and the other test lead to the negative (-) battery terminal. Continuity should be measured (Figure 39). NOTE: When inserting a test lead into the ECU connector, use caution to not damage terminals Figure 38 If the proper fuel pressure is not present, repair and/or replace the fuel delivery system, then re-test the fuel pressure as described above. If fuel pressure is acceptable, go to TEST 5 - Check ECU Inputs. TEST 5 - Check ECU Inputs The ECU needs to receive several inputs before an engine start will occur. It must receive: A connection to battery negative (-) terminal through Pin #10, Wire #0. Battery voltage during engine crank at Pin #15, Wire #14A. Battery voltage during engine crank at Pin #5, Wire #14B. Battery voltage at Pin #11, Wire #15A. Battery voltage at Pin #3, Wire #56A. A frequency signal at Pins #22 and #23 from the engine RPM sensor. When all of these conditions are present the ECU will connect Wire #56A and #14B to ground. This closes the Power Relay to supply battery voltage to the ignition and engine alternator, and opens the fuel solenoid. Figure If continuity is measured, proceed to Step 6. If no continuity is measured, repair/ replace wiring between Pin #10, Wire #0and the negative (-) battery terminal. 6. Set the meter to measure DC Voltage. Connect the positive (+) meter test lead to Pin #15, Wire #14A, and connect the negative (-) meter test lead to battery ground (Figure 40). Figure 40 43

48 2 7. Reinstall the 15 Amp fuse in the system control panel. 8. Turn SYSTEM switch to AUTO. 9. While observing the meter, push and hold the MANUAL OVER-RIDE button. Battery voltage should be measured. Turn SYSTEM switch to OFF. If battery voltage is measured, proceed to Step 10. If no voltage is measured, repair/ replace wiring between Pin #4, Wire #14 on the CMA and Pin #15,Wire #14A on the ECU. 10. Insert positive (+) meter test lead to Pin #5, Wire #14B and the negative (-) meter test lead to negative (-) battery terminal (Figure 41). 5 Figure If battery voltage is measured, proceed to Step 14. If no voltage is measured, repair/ replace fuses and/or wiring between the positive (+) battery terminal and Pin #11, Wire #15A on the ECU. 14. Insert positive (+) meter test lead topin #3, Wire #56A and negative (-) meter test lead to battery (-) negative terminal. Battery voltage should be measured (Figure 43). 3 Figure Turn SYSTEM switch to AUTO. 12. While observing the meter, push and hold the MANUAL OVER-RIDE button. Battery voltage should be measured. Turn SYSTEM switch to OFF. If battery voltage is measured, proceed to Step 13. If no voltage is measured, repair/ replace wiring between Pin #4, Wire #14A on the CMA and Pin #5, Wire #14B on the ECU. 13. Insert positive (+) meter test lead to Pin #11, Wire #15A and negative (-) meter test lead to battery negative (-) terminal. Battery voltage should be measured (Figure 42). Figure 43 If battery voltage is measured, proceed to Step 15. If no voltage is measured, repair/ replace fuses, wiring and/or power relay between positive(+) battery terminal and Pin #3,Wire #56A on the ECU. 15. Set meter to measure Ohms (Ω). 16. Insert one test lead into Pin #22 and the other meter test lead into Pin #23 (Figure 44). 44

49 Unscrew RPM sensor one complete rotation. 5. While holding sensor in position, tighten lock nut. Figure Approximately Ohms should be measured. If resistance is outside of this range, check for open/shorted wiring or RPM sensor. If resistance is within specifications, make sure RPM sensor is adjusted correctly as described below. If RPM sensor is adjusted correctly and the engine still does not start, contact Power Solutions Inc.(PSI Technical Service Specialists, or at: for further engine troubleshooting. 2 To Adjust RPM Sensor: 1. Remove the RPM sensor (Figure 45,A). Figure Position a flywheel tooth in the center of the RPM sensor mounting hole. 3. Install RPM sensor and tighten until sensor lightly touches the flywheel tooth. 45

50 2 Figure 46 46

51 CRANKING FAILURES TEST 1 - Check Battery Components 1. Check the condition and electrical integrity of all wires, connectors, and cables throughout the home standby unit. Some areas of particular focus are: Battery state of charge and connections Generator grounds, wiring, and connections Repair any discrepancies and proceed to Step Attempt a MANUAL OVER-RIDE start and observe system. If generator starts repair is complete. Reset exercise timer and return generator to AUTO. If generator fails to start, proceed to Step Remove and inspect the 15 Amp Control Panel fuse. A blown fuse indicates a shorted circuit. Repair any shorts and replace fuse. If fuse is okay, proceed to Step Inspect the 50 Amp fuse in Wire #13 located close to the starter motor (Figure 47,A). Figure 47 If the fuse is good, proceed to TEST 2 - Check Starter Contactor Signal. A blown fuse indicates a short in the circuit. Inspect the circuit and repair any shorts. Replace fuse. TEST 2 - Check Starter Contactor Signal 1. Set meter to measure DC Voltage. Connect positive (+) test lead to Wire #56 at the starter contactor (Figure 48). Figure Connect negative (-) test lead to battery ground terminal. 3. Make sure SYSTEM switch is in AUTO. While observing the meter, push and hold the MANUAL OVER-RIDE start button. Battery voltage should be measured. If no voltage is measured on WIRE #56 at the starter contactor, proceed to TEST 3 - Check System Control Panel Output. If battery voltage is measured at the starter contactor but the starter motor does not engage, verify engine ground connections are good. Once all connections are good, contact Power Solutions, Inc. (PSI Technical Service Specialists, or at: Service@PowerGreatLakes.com) for further troubleshooting on the starter and engine. TEST 3 - Check System Control Panel Output 1. Turn the SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Gain access to the system control panel. SEE HOW TO ACCESS SYSTEM CONTROL PANEL ON PAGE Insert the positive (+) test lead to Wire #56,Pin #3 (Figure 49) and the negative (-) test lead to the battery ground terminal. 2 47

52 2 Figure 50 Figure Reinstall the 15 Amp fuse in the system control panel. 6. Put the SYSTEM switch in AUTO. 7. While observing the meter, push and hold MANUAL OVER-RIDE start button. Battery voltage should be measured. If battery voltage is measured at Wire #56,Pin #3, but is not measured at the starter contactor as described in TEST 2, Step 3, repair/replace wiring between the system control panel and starter contactor. If no voltage is measured, proceed to TEST 4 - Check System Control Panel Inputs. TEST 4 - Check SCP Input 1. Turn SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Set the meter to measure DC Voltage. 4. Connect the positive (+) meter test lead to Pin #1, Wire # 15A and the negative (-) meter test lead to battery ground terminal. (Figure 50). Battery voltage should be measured. If battery voltage is measured at Wire #15A, Pin #1 but was not measured during the test at TEST 3, Step 4-7, verify system control panel ground at Wire #0, Pin #2. If ground is present, replace the system control panel. If no voltage is measured, proceed to Step Turn the SYSTEM switch to OFF. 6. Remove the 15 Amp fuse from the system control panel. 7. Remove the system control panel cover to gain access (Figure 51). Figure Locate and inspect the 20 Amp ECU fuse (Figure 52,A). 48

53 Figure 52 2 A blown fuse indicates a short in the circuit. Because this fuse is designed to protect the ECU and its functions, a blown fuse would likely be related to something in the ECU or throttle control. For troubleshooting information, contact Power Solutions, Inc.(PSI Technical Service Specialists, or at: Serice@PowerGreatLakes.com) Repair or replace any shorts and replace the fuse, then proceed to TEST 2 - Check Starter Contactor Signal. If the fuse is good, proceed to Step Set meter to measure DC Voltage. 10. Measure for battery voltage at the ECU fuse line side, Wire #15. If voltage is present at the fuse but not present at Wire #15A, Pin #1 on the system control panel, repair/replace wiring between the fuse and system control panel. If no voltage is present, repair/replace wiring between the 50 Amp fuse and the ECU fuse. 11. When wiring repair is complete, retest to verify repair. 12. Reset exercise timer and return generator to AUTO. 49

54 2 50

55 2 Figure 53 51

56 2 (FC_5) UNDER FREQUENCY The troubleshooting steps for under-and overfrequency faults are identical. Refer to Fig. 29 to troubleshoot (FC_5) & (FC_6) fault indications. The low frequency shutdown feature is designed to protect the generator and its loads from an output frequency that is too low. The system control panel senses frequency at Wire # L1 and Wire #L2. If output frequency drops below 55 Hz for three seconds, the system control panel will shut down the generator. The digital display will show FC-5 and the remote LED will repeatedly flash five times with a pause. Under frequency may be caused by: A restricted air filter A failure in the generator sense wiring (L1 or L2) A failed engine governor Problems with the fuel delivery system Excessive loads A failure at the system control panel An engine that is not producing sufficient power WARNING Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. TEST 1 - Check No-Load & Full-Load Frequency For the following procedures, we recommend the use of Briggs & Stratton Tach and Hour meter (#19389) and Briggs & Stratton Frequency Meter (#19543) with Frequency Adapter (#19580). CAUTION Follow the manufacturer s instructions for the type of frequency meter that you are using. Perform the following tests under full electrical loads with all gaseous fuel appliances turned ON and operating. No-Load RPM specification is /- 100 RPM / Hz Full-Load RPM specification is /- 100 RPM / Hz Check No-Load Frequency 1. Turn the SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Remove the circuit breaker cover. 4. Make sure the generator circuit breaker is ON. 5. Reinstall the 15 Amp fuse in the system control panel. 6. Set SYSTEM switch to AUTO, then push and hold MANUAL OVER-RIDE to start the unit. 7. Measure frequency at the load side of the circuit breaker (Figure 54). 52

57 2 Figure 55 Figure 54 Check Full-Load Frequency 1. Turn off Utility power to the transfer switch. The generator should start and the transfer switch should transfer. Slowly add electrical loads to the generator unit until it is running at full capacity. 2. Measure the frequency at the load side of the circuit breaker. If the frequency is correct, restore utility power then proceed to TEST 2 - Measure Frequency L1 & L2. If the frequency is not correct: 1. Verify fuels pressure and volume are within specifications. 2. Verify the air filter is not clogged. If the engine speed is still too low, contact Power Solutions, Inc. (PSI Technical Service Specialists, or at: Serice@PowerGreatLakes.com) for governor troubleshooting information. NOTE: If a full-load adjustment was required, recheck the frequency at no-load. TEST 2 - Measure Frequency at L1 & L2 1. Gain access to the system control panel. SEE HOW TO ACCESS SYSTEM CONTROL PANEL ON PAGE Inspect position of jumper on JP1 (Figure 55,A). Jumper position must be located as shown for 60Hz application. 3. With the unit running, measure the frequency at L1 and L2 at the system control panel pins (Fig 56). Figure 56 If the frequency is not correct, replace/ repair the wiring between the circuit breaker and L1 & L2 at the system control panel. Then re-test the frequency at L1 & L2. If the frequency is correct but the generator continues to shut down for low frequency, replace the system control panel board. 4. Reset the exercise timer. SEE RESETTING THE EXERCISE TIMER ON PAGE

58 (FC_6) OVER FREQUENCY The troubleshooting steps for under and over frequency faults are identical. Refer to (Figure 30) to troubleshoot (FC_5) & (FC_6) fault indications. WARNING 2 Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. NOTE: Over-frequency is a symptom of a governor related issue. Contact Power Solutions Inc. (PSI Technical Service Specialists, or at: Service@PowerGreatLakes.com) for troubleshooting on the electronic governor. The CMA/Control Panel monitors generator output frequency at Wire # L1 & L2. If the generator output frequency increases to 65Hz- 70Hz, the system control panel waits three seconds before shutting the unit down. Should the frequency exceed 70Hz, the system control panel will shut down the generator immediately after starting. The reason for the 5Hz latitude in frequency sensing is that the engine governor will hunt somewhat before it finds the desired setting. This causes variable frequency outputs that are not harmful until they reach the 65Hz - 70Hz range. If the system control panel senses an overfrequency condition, the digital display will show FC_6 and the remote LED will repeatedly flash six times with a pause. 54

59 2 Figure 57 55

60 2 (FC_7) HIGH TEMPERATURE The contacts of the Over Temperature Switch (OTS) are normally open. If the engine coolant reaches a critical temperature, the switch contacts will close and complete a circuit to ground through Wire # 95. If the system control panel senses this ground, it will shut down the generator. The digital display will show FC_7 and the remote LED will repeatedly flash seven times with a pause. Common causes for high temperature include: Running the unit with the side doors removed Obstructed air inlet or exhaust port Debris in the radiator cooling fins Loose fan belt Low coolant level Contact Power Solutions, Inc. (PSI Technical Service Specialists, or at: Serice@PowerGreatLakes.com) for overheating caused by an engine component, such as a leaking gasket, water pump, or a faulty thermostat. Inspect for and correct any of these conditions before checking the OTS. Once the problem is corrected, reset the fault code detection system. SEE RESETTING FAULT CODE DETECTION SYSTEM ON PAGE 19. WARNING Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. TEST 1 - Check Over-Temperature Switch 1. Turn SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Remove Wire #95 (A) from the OTS. Make sure the wire does not touch the ground. 4. With the engine at room temperature test for continuity of the switch (Figure 58). Figure 58 If no continuity is measured, the switch is good. Proceed to TEST 2 - Check Wire #95. If continuity is found, replace the OTS. 5. Reconnect the wiring, install fuse and reset the exercise timer. SEE RESETTING THE EXERCISE TIMER ON PAGE 13. TEST 2 - Check Wire # Turn SYSTEM switch to OFF. 2. Remove the 15 Amp fuse from the system control panel. 3. Gain access to the generator control panel. SEE HOW TO ACCESS THE SYSTEM CONTROL PANEL ON PAGE Remove the 8-pin connector from the system control panel board (Figure 59). 56

61 Figure Remove wire and measure for short-toground between Wire #95 and ground (Figure 60). Figure 60 If a short-to-ground is measured, repair and/or replace the wiring as necessary. If no short-to-ground is measured, replace the system control panel. 6. Reset the exercise timer. SEE RESETTING THE EXERCISE TIMER ON PAGE