Download - 12k Service Manual

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Model 1815 (12kW) Table of Contents

Service & Troubleshooting Guide - Home Generator Systems

SAFETY RULES 5

In the Interest of Safety 5

Safety Practices 6

ACCESS TO THE GENERATOR 7

GENERATOR COMPONENTS 8

SYSTEM CONTROLS 9

GENERATOR CLEARANCES 10

FUEL FACTORS 10

Power Decreases at Altitude & Temperature 10

STARTING GENERATOR (NO LOAD) 10

Electrical Checks 11

AUTOMATIC OPERATION 11

Sequence of Automatic Events 11

Utility Voltage Droupout Sensor 12

Engine Warm-up Time Delay 12

Backup Voltage Sensor 12

Utility Voltage Pickup Sensor 12

Retransfer Time Delay 12

Engine Cool-down Timer 12

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 14

CIRCUIT INFORMATION 15

Power During Fault Conditions 15

Control Module Assembly (CMA) 15

LED Fault light Conditions 16

Resetting Fault Detection System 16

Trickle Charge Operation 16

FUEL SUPPLY 16

CONTROL MODULE CONNECTORS 17

TRANSFER SWITCH MODULE CONNECTORS 17

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 PressureTroubleshooting Procedure: 22

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

Low VoltageTroubleshooting Procedure: 23

Engine Fails To Start: (Four Blinks [ • • • • ]) 25

Troubleshooting Procedure: 25

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 [ • • • • • • ]) 31

Over Frequency Troubleshooting Procedure: 31

High Oil Temperature: (Seven Blinks [ • • • • • • •]) 32

High Oil Temperature Troubleshooting Procedure: 32

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GENERAL INFORMATION

TROUBLESHOOTING

MODEL 1815 (12KW)

SPECIFICATIONS 36

Generator 36

Engine 36

ENGINE MAINTENANCE 38

Checking Oil Level 38

Changing Oil & Filter 38

Replacing The Spark Plugs 38

Service The Air Cleaner 39

Inspect Spark Arrester Screen 39

Engine Governed Speed 39

Valve Lash 39

Carburetor Adjustments 39

Engine Adjustment 40

12KW RESISTANCE VALUES 41

System Interconnections 41

12kW Circuit Test Introduction 42

Checking The Stator Power Winding Through The Harness 43

Checking The Battery Charge Winding (BCW) Through The Harness 43

Checking The Excitation Circuit 44

Checking The Stator Power Winding 44

Checking The Battery Charge Winding (BCW) 45

Checking The Rotor Winding 45

REMOVING THE MECCALTE GENERATORRoof Removal 47

Muffler Box Removal 47

Remove Fuel Line From Regulator 48

Alternator Bulkhead Removal 49

Removing The Generator 51

Blind End Cover Removal 51

Generator Isolation Mounts 51

Removing Stator Mounting Hardware 51

Removing Rotor Through-Bolt (Stay Shaft Bolt) 52

Removing The Rotor Assembly 53

Inspecting The Rotor Assembly 54

Generator Schematic 56

Transfer Switch Schematic 57

50 Amp Wiring Diagram 58

200 Amp Wiring Diagram 60

200 Amp with Main Line DisconnectWiring Diagram 62

Oil Heater 64

240 Volt Battery Warmer 66

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Model 1815 (12kW) Table of Contents


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GENERATOR ASSEMBLY

APPENDIX

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Model 1815 (12kW) General Information


GENERAL INFORMATION

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SAFETY RULES


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In the Interest of SafetyThis manual outlines the construction,function and servicing procedures ofthe Briggs & Stratton Power Products®Home Standby generator series. It isstructured for use by trainedtechnicians that are working in andfrom a properly equipped shop.Familiarity with the proper method ofusing tools, measuring equipment andworkshop procedures are essential toperforming successful maintenance andrepair on this equipment.

Ensure that all specified tools and/orequipment are available beforeattempting to service this equipment.

For a detailed discussion of thefundamental principles involved withthe physics of electrical powergeneration, refer to the Familiarizationand Troubleshooting Guide(Publication #86262 Revision 3 orlater). This manual is available throughyour Briggs & Stratton CentralDistributor.

Safety Alert Symbols

NOTE: This notation is usedto inform you of a method,reference or procedure thatcould assist with specificoperations or decisions.

CAUTION: When used without thealert symbol, indicates a situation thatcould result in damage to equipment.

• When using generator for backuppower, notify utility company. Useapproved transfer equipment to isolategenerator from electric utility.

• Use a ground fault circuit interrupter(GFCI) in any damp or highlyconductive area, such as metal deckingor steel work.

• Do not touch bare wires orreceptacles.

• Do not use generator with electricalcords which are worn, frayed, bare orotherwise damaged.

• Do not handle generator or electricalcords while standing in water, whilebarefoot, or while hands or feet arewet.

• Do not allow unqualified persons orchildren to operate or servicegenerator.

Generator producespowerful voltage.

Failure to isolate generatorfrom power utility can resultin death or injury to electricutility workers due tobackfeed of electrical energy.

DANGER

• Do not touch hot surfaces.

• Allow equipment to cool beforetouching.

Running engines produceheat. Temperature of mufflerand nearby areas can reachor exceed 150°F (65°C).

Severe burns can occur oncontact.

DANGERDANGER: Indicates a hazardwhich, if not avoided will resultin death or serious injury.

WARNING: Indicates a hazardwhich, if not avoided couldresult in death or seriousinjury.

CAUTION: Indicates a hazardwhich, if not avoided mightresult in death or seriousinjury.

The safety alert symbol ( ) is usedto identify safety information abouthazards that can result in personalinjury. A signal word (DANGER,WARNING, CAUTION) is usedwith the alert symbol to indicate thepotential severity of injury. In addition,a hazard symbol may be used torepresent the type of hazard.

HAZARD SYMBOLS AND MEANINGS

Toxic Fumes Electrocution

Hot Surface Chemical Burns

Explosive Pressure

Kick Back EntanglementDisconnectSpark Plug

Fire

Read Goggles

Explosion

• National electric code requiresgenerator to be properly grounded toan approved earth ground. Call anelectrician for local groundingrequirements.

Failure to properly groundgenerator can result inelectrocution, especially if thegenerator is equipped with awheel kit.

DANGER

The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects,or other reproductive harm.

WARNING

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Safety Practices

• Do not attempt to modify theunit or use it for any applicationit was not designed for. If youhave any questions about yourgenerator's application, ask yourdealer or consult the factory.

• Read these procedures carefullyand become familiar with yourgenerator set. Know itsapplications, its limitations andany hazards involved.

• Never handle any kind ofelectrical cord or device whilestanding in water, whilebarefoot, or while hands or feetare wet.

• Do not use worn, bare, frayedor otherwise damaged electricalcord sets with any generatorset. Using a defective cord mayresult in an electrical shock ordamage to the test equipmentand/or the unit.

• These units require an adequateflow of cooling air for theircontinued proper operation.Never operate or service anyunit while inside any enclosurewhere the free flow of coolingair into and out of the unitmight be obstructed. Withoutsufficient cooling airflow, theunits quickly overheat, damagingthe generator and/or nearbyproperty.

• Home Standby generatorsproduce a high voltage that cancause an extremely dangerouselectrical shock. Avoid contactwith bare wires, terminals, etc.Never permit an untrainedperson to service or assist withthe procedures discussed in thisguide.

• Never start or stop a unit withelectrical loads connected toreceptacles and with theconnected loads turned ON.Start the engine and let itstabilize before connecting anyelectrical loads. Turn OFF anddisconnect all electrical loadsbefore shutting down anygenerator.

• The manufacturer could notpossibly anticipate everycircumstance that might involvea hazard. For that reason,warnings in manuals andwarnings on tags or decalsaffixed to the units are not all-inclusive. Do not handle,operate or service a unit with aprocedure or method notspecifically recommended by themanufacturer.

• This entire book is filled withimportant safety information - please read it carefully.

• Do not allow any open flame, spark,heat, or lit cigarette around batteryduring, and for several minutes aftercharging.

• Wear protective goggles, rubberapron, and rubber gloves.

Storage batteries give offexplosive hydrogen gasduring recharging.

Hydrogen gas stays aroundbattery for a long time afterbattery has been charged.

Slightest spark will ignitehydrogen and causeexplosion.

You can be blinded orseverely injured.

Battery electrolyte fluidcontains acid and isextremely caustic.

Contact with battery fluidwill cause severe chemicalburns.

DANGER

• This generator does not meet U.S.Coast Guard Regulation 33CFR-183 andshould not be used on marineapplications.

• Failure to use the appropriate U.S.Coast Guard approved generator couldresult in bodily injury and/or propertydamage.

WARNING

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ACCESS TO THE GENERATOR



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The Home Generator System is equipped with an enclosurethat has four access doors (Figure 1). The doors are namedfor the significant component located behind them. Startingwith the side that has the fuel connection and proceedingclockwise, the doors are named:

OIL SERVICE DOOR

AIR INTAKE DOOR

CONTROL PANEL DOOR

BATTERY DOOR

Each Home Generator System is equipped with threeidentical keys. These keys fit the locks that secure the oilservice and control panel doors.

To remove an access door:

• Insert a key into the lock of the access door you wishto remove and turn one quarter turn clockwise.

NOTE: The key is retained in the lock when thelocks are open.

• Grasp the door’s lift handle and pull the door upwardsuntil 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 andout of the upper door channel. The door will comefree of the generator enclosure.

The AIR INTAKE DOOR does not have locks or lifthandles. You must remove a locking screw found directlyabove the center of the door. They are removed in thesame way the locking doors are removed. To secure theseaccess doors, replace the locking screws.

To install an access door:

• Support the door by grasping the lift handle or louver.Guide the top of the door into the generatorenclosure.

• Lift the door up into its upper channel until the securitypins clear the sill of the enclosure.

• Push the lower half of the door into the door recessuntil it is flush with the sides.

• Seat the door by pushing it down until the rubbercoated security pins engage and the door rests on themounting sill.

• When installing a lockable door, turn the key onequarter turn counterclockwise and remove the key.

CAUTION: Do not operate thebackup generator unless the OILSERVICE and/or CONTROL PANELdoors are installed. Failure to do so willcause overheating.

WARNING

• Carelessness could cause severeburns.

The exhaust port can reach atemperature of 600°F andremains hot after shutdown.

Figure 1 — Enclosure Access Doors

Air Intake Door

Door Lock Screw

Fuel Inlet

Oil Service Door

Exhaust Port

DoorLock

Screw

Battery Door Control Panel Door

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GENERATOR COMPONENTS



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15 Amp Fuse — Protects the DC control circuits.

Air Cleaner — Uses a dry type filter element and foamprecleaner to prevent dirt and dust from being drawn intothe engine.

Battery — 12 VDC, 33 Amp-Hour sealed battery providespower to start the engine. Battery receives trickle chargewhenever generator is not running.

Control Panel — Used for various test, operation andmaintenance functions. See THE SYSTEM CONTROLPANEL on the next page.

Engine Label — Identifies engine model and type.

Exhaust Port — High-performance muffler lowers enginenoise to comply with most residential codes.

Oil Dip Stick — Used to check the engine oil level.

Oil Drain Hose — Provided to facilitate changing oil.

Oil Fill Cap — Remove to service the engine withrecommended oil.

Oil Filter — Filters engine oil to prolong engine life.

Unit Data Decal — Identifies unit by serial number.

Figure 2 — Generator Components

Exhaust Port

Control Panel

15 Amp Fuse

Unit Data Decal

Oil Drain Hose

Oil Filter

Control Panel Door Opening

Battery Door Opening

Battery

Engine Label

Oil Service Door Opening

Air Cleaner

Oil Filler Cap

Oil Dipstick

Fuel Inlet

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SYSTEM CONTROLS



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15 Amp Fuse — Protects the Home Generator SystemDC control circuits. If the fuse has blown (melted open) orwas removed, the engine cannot crank or start. Replace thefuse using only an identical BUSS AGC 15A fuse.

AUTO/OFF/MANUAL Switch — This three-positiondevice is the most important control on the system and isused as follows:

• AUTO position is the normal operating position. If autility power outage is sensed, the system will start thegenerator. When utility power is restored, and theinternal engine temperatures stabilize, it shuts off thegenerator, and waits for the next utility power outage.While waiting, it maintains battery with trickle charge.

• OFF position turns off running generator, takes systemout of Automatic mode and resets any detected faults.

• MANUAL position starts the engine but does notdisconnect from utility power. It is used formaintenance or diagnostic functions.

Circuit Breaker — Protects the system from shorts andother over-current conditions. Must be ON to supplypower to the Automatic Transfer Switch.

Diagnostic LED — Used for troubleshooting operationalproblems with the Home Generator System. All faultconditions are described in the section LED Fault LightConditions.

Hour Meter — The hour meter records the total numberof hours the generator has been running and is used toschedule maintenance tasks.

Set Exercise Switch — Used to set the exercise cyclestart time and day-of-the-week. Exercise cycle only occursin AUTO mode.

Figure 3 — System Control Panel

Diagnostic LED

AUTO/OFF/MANUAL switch

Set Exercise Switch

Hour Meter

Circuit Breaker

15 Amp Fuse

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Generator Clearances

The generator enclosure should be a minimum of 3 ft. (.9meter) from combustible material. At least 3 ft. (.9 meter)of access room all around the enclosure should be available.

The unit’s exhaust port should be at least 5 ft. (1.5 meter)from any building opening (window, door, vent etc.), and theexhaust gases should not be able to accumulate in anyoccupied area (Figure 4).

Fuel Factors

For proper engine function, the following fuel guidelines arerecommended:

• Clean, dry fuel, which is free of moisture or anyparticulate material should be used.

• A manometer port should have been provided (Figure 5).

Power Decrease at High Altitude or HighTemperature

Air density is less at high altitudes, resulting in less availableengine power. Specifically, engine power will decrease 3.5%for each 1,000 feet (300 meters) above sea level and 1% foreach 10° F (5.6°C) above 77°F (25°C). Make sure thesefactors have been considered when determining totalgenerator load output.

Starting The Generator (No Load)Begin testing the system without any electrical loadsconnected, as follows:

• Set the AUTO/OFF/MANUAL switch to OFF.

• Set the generator’s main circuit breaker to its OFF(open) position.

• Install the 15 Amp fuse in the control panel.

• Set the AUTO/OFF/MANUAL switch to MANUAL.

NOTE: If the Home Generator System has beenidle for an extended period, it may require that air inthe gaseous fuel lines be purged. This may take a fewminutes.

• The unit will go through its starting cycle.

• If unit failed to start, reset fault light and make sure thefuel is ON.

• Listen for unusual noises, vibration or other indicationsof abnormal operation. Check for oil leaks, evidence ofoverheating etc. while the unit runs.

Figure 4 — Home Generator System Clearances

Figure 5 — Manometer Port

CAUTION

• Do not operate the equipment if the fuel shut-offvalve is missing or inoperative.

This equipment isequipped with anautomatic safety gas fuelshut-off valve.

Exhaust port must be5ft. (1.5 meter) mini-mum distance frombuilding openings.

Exhaust Port

Flexible Hose

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Electrical Checks

With the AUTO/OFF/MANUAL switch set to OFF:

• Turn ON the main distribution panel circuit breakerthat supplies utility power to the Automatic TransferSwitch.

• Use a true RMS AC voltmeter to check utility powervoltage across UTILITY CONNECTION lugs in theAutomatic Transfer Switch. Nominal line-to-line voltageshould be about 240VAC.

• Check utility power between one of the UTILITYCONNECTION lugs and the neutral lug, then betweenthe other UTILITY CONNECTION lug and the neutrallug. Nominal line-to-neutral voltage should be 120VAC.

• Set the generator's main circuit breaker to the OFFposition. Initial tests will be conducted at no-loadcondition.

• Set the AUTO/OFF/MANUAL switch to MANUAL.The engine should crank and start.

• Let the engine warm up for about five minutes to allowinternal temperatures to stabilize. Then, set thegenerator’s main circuit breaker to its ON (closed)position.

• Connect a true RMS AC voltmeter and a frequencymeter to check generator output across GENERATORCONNECTION lugs in the Automatic Transfer Switch.Voltage should be about 240VAC, frequency should be62.0 - 62.5 Hz.

NOTE: If either parameter is outside these ranges,perform the Engine Adjustments described on page40.

• Check generator output between one of theGENERATOR CONNECTION lugs and the neutral lug,then between the other GENERATOR CONNECTIONlug and the neutral lug. In both cases, voltage readingshould be about 120VAC.

• Set the generator’s main circuit breaker to OFF.

• Set the AUTO/OFF/MANUAL switch to OFF. Engineshould shut down.

IMPORTANT: Do not proceed until you arecertain that generator AC voltage and frequency arecorrect and within the stated limits. To obtain theproper generator frequency, see Engine Adjustmentson page 40.

Automatic OperationTo select automatic transfer operation, do the following:

• Set the main distribution panel circuit breaker thatsends utility voltage to the transfer switch to ON.

• Set the AUTO/OFF/MANUAL switch to AUTO.

• Set the generator’s main circuit breaker to its ONposition.

Sequence Of Automatic Events

The generator’s control panel houses a logic control circuitboard. This control board constantly monitors utility powersource voltage. Should that voltage drop below 70%, controlboard action will signal the engine to crank and start. Afterthe engine starts, the control board signals the transferswitch to activate and connect the protected house circuitsto the Home Generator System.

When utility source voltage is restored above the 80%voltage level, the control board signals the transfer switch totransfer loads back to the utility source. After retransfer,the engine is signaled to shut down after about 1 minute forcool-down.



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DANGER

The Automatic Transfer Switchis now electrically energized(Hot). Contact with HOT partswill result in extremelyhazardous and possibly fatalelectrical shock..

• Proceed with caution.

DANGER

Generator output voltage is nowsupplied to the AutomaticTransfer Switch. Contact withenergized Automatic TransferSwitch parts will result indangerous and possibly fatalelectrical shock.

• Proceed with caution.

The actual system operation is not adjustable and issequenced by sensors and timers on the control board, asfollows:

Utility Fail

- Utility voltage sensor senses when utility voltage is below70% of nominal. Engine start sequence is initiated after 6-second delay.

Engine Warm-up Time Delay

- Time delay to allow engine warm-up before transfer fixedat 20 seconds or 50 seconds with optional cold weatherpackage.

Utility Voltage Pickup Sensor

- Voltage pickup level is 80% of nominal voltage.

Retransfer Time Delay

- Retransfer from standby to utility supply 10 seconds afterutility voltage is above pickup level.

Engine Cool-down Timer

- Engine will run for 60 seconds after retransfer.

Testing of The Automatic Transfer Switch.

Turn the main service disconnect to the OFF position. Theautomatic sequence will follow. To go back to utility power,turn the main service disconnect to the ON position.

Generator AC Connection System

A single-phase, three-wire AC system is used in the HomeGenerator System. The stator assembly consists of a pair ofstationary windings with two leads brought out of eachwinding. The two windings are connected together in series,resulting in a fixed 240VAC, 60Hz output. Stator outputleads #11 and #44 are the two hot leads. The junction ofleads #22 and #33 form the neutral lead(Figure 6).

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Figure 6 — System (AC) Connections

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Checking Automatic OperationTo check the system for proper automatic operation,proceed as follows:

• Check that AUTO/OFF/MANUAL is set to OFF.

• Apply utility power to the UTILITY CONNECTIONlugs of the Automatic Transfer Switch by turning ONthe main distribution panel circuit breaker.

• Set the AUTO/OFF/MANUAL switch to AUTO. TheAutomatic Power System is now ready for automaticoperation.

• Turn OFF the main distribution panel circuit breakerthat sends utility power to the automatic transferswitch.

The engine will crank and start once the utility voltage dropsout and the sensor has timed out. After starting, the transferswitch will transfer the circuit loads to the generator. Letthe system go through its entire automatic operationsequence.

• With the generator output supplying its loads, turn ONthe main distribution panel circuit breaker that suppliesutility power to the transfer switch.

• After about 5 minutes of run-time, the automatictransfer switch will transfer loads back to the utilitypower.

• About one minute after re-transfer, the engine will shutdown.

This completes the test procedures for automatic operation.The Home Generator System will now start automaticallywhen utility power is lost and will supply power to theprotected circuits in the home.

Stopping the System

To disable the power transfer system for maintenance:

• Ensure that utility power is ON and is supplied to theUTILITY CONNECTION lugs of the transfer switch.


• Set the generator’s main circuit breaker to its OFFposition.

Generator Load Tests To test the generator with electrical loads applied, proceedas follows:

• Set the generator’s main circuit breaker to OFF.


• Turn OFF the main circuit breaker, which suppliesutility power to the UTILITY CONNECTION lugs ofthe Automatic Transfer Switch.

• Set AUTO/OFF/MANUAL switch to AUTO.

Engine should crank and start immediately.

• Set the generator’s main circuit breaker to ON.(Generator power is now supplied to theGENERATOR CONNECTION lugs of the transferswitch).

• Turn ON electrical loads. Apply the full rated output ofthe selected circuits to the generator system.

• Use an accurate AC voltmeter to check generatoroutput voltage across the primary load lugs that supplypower to the protected circuits. Voltage should beequal to or greater than 216VAC.

• Connect an accurate AC frequency meter across theprimary load lugs of the protected circuits. Frequencyshould be 62-62.5 Hz.

• Let the Home Generator System run loaded for 20-30minutes. Listen for unusual noises, check for excessivevibration or other indications of abnormal operation.Check for oil leaks, evidence of overheating etc.

• Turn the Main Distribution Circuit Breaker ON(This supplies utility power to the UTILITYCONNECTION lugs of the transfer switch).

The transfer switch should transfer back to utility, thegenerator will cool down for 1 minute and then shut down.



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Reconfiguring The Fuel SystemThe engine of your Home Generator System is factorycalibrated to run on natural gas (NG). It may also beoperated on liquefied petroleum (LP). There is no additionalhardware/equipment required to switch between either fuel.However, LP fuel inlet pressure must be between 11 and 14inches water column.

To reconfigure the fuel system for LP use:


• Set the generator’s main circuit breaker OFF.

• Remove the 15 Amp fuse.

Activate the fuel transfer solenoid as follows:

• Remove the Oil Service access panel.

• Connect the two-pin electrical connector shown infigure 7. Use the short adapter cable, if supplied.

• Reinstall the Oil Service access panel.

• Reinstall the 15 Amp fuse.

• Set the generator’s main circuit breaker ON.


The system is now ready to operate automatically using LPfuel. With a fixed main jet for LP gas, there is no need toperform any engine adjustments for LP operation.

Setting Exercise TimerThe Home Generator System is equipped with an exercisetimer that will start and exercise the system once everyseven days. During this exercise period, the unit runs forapproximately 20 minutes and then shuts down. Electricalload transfer does not occur during the exercise cycle(unless a utility power outage occurs).

A switch on the control panel is labeled Set Exercise(depicted on page 9). The specific day and the specific timeof day this switch is pressed is programmed into the controlboard memory. This date and time is then used toautomatically initiate the system exercise cycle.

To perform the SET EXERCISE procedure:

• Choose the day and time you want your HomeGenerator System to exercise.

• On that day and time, set the AUTO/OFF/MANUALswitch to OFF.

• Press and hold down the SET EXERCISE switch. TheDiagnostic LED will turn on.

• Release the Set Exercise switch.

• Set the AUTO/OFF/MANUAL switch to AUTO. Set Exercise is complete.

For example, if you press the SET EXERCISE switch onSunday morning at 10:00 AM, the unit will run an exercisecycle the following Sunday at 10:00 AM.

NOTE: SET EXERCISE will only work if the unit isin the Automatic mode and this exact procedure isfollowed. The exerciser does not need to be re-set ifthe 15 Amp fuse is removed or changed. Theexerciser will need to be re-set if the 12 VDCbattery is disconnected.

If you want to change the day and time the unit exercises,simply perform the SET EXERCISE procedure on the exactday and time you want it to take place.

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Figure 7 — Fuel Transfer Solenoid Connection

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Power During Fault ConditionsWhenever the Home Generator System is in anuncorrected fault condition, the automatic transfer switchresets to UTILITY POWER. This means that when utilitypower is restored, it will automatically be applied to all thecircuits in the home.

Control Module Assembly (CMA)The Control Module Assembly (CMA) is a printed circuitboard containing all the logic circuits that operate andprotect the generator. It is located inside the generatorenclosure behind the AIR INTAKE DOOR. It is the controlcenter of the generator. Its functions depend on the inputfrom various circuits throughout the standby installation.Before replacing the CMA, all other circuits must be testedto ensure proper operation. When a failure in the CMA hasbeen determined, the CMA must be replaced as a completeassembly because its individual parts are not serviceable.

The functions of the CMA include:

• Battery Trickle Charge

• Set Exercise Timer

• Manual Start

• Sensing Utility Voltage

• Automatic Start, in event of utility failure

• Automatic Engine Cool-Down Timer

• Fault Detection and Automatic Shutdown

• Fault Light Indication (Diagnostic LED)

To gain access to the CMA, refer to figure 8,views A, B & C.

1. Remove the locking screw and the AIR INTAKEDOOR (View A).

2. Remove the three screws holding the shield markedDanger High Voltage (View B).

The location of the Control Module Assembly (CMA) isshown in view C.

The CMA is connected to its various circuits through an 18-pin connector that is mounted to the board itself.

When directed to measure an electrical value, the locationof the measurement is shown in the form of a picture andthe corresponding pin of the connector is shaded in agraphic illustration that is specific to each test beingperformed (Figure 9).

A detailed illustration of the entire connector, as well as thefunctions of each individual pin, is given on page17.

CIRCUIT INFORMATION



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Figure 9 — Test Points & Graphic Illustration

P-18

P-17

P-16

P-11

P-12

P-13

P-10

P-7

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

W-241

W-T2

W-85

W-95

W-66

W-170

W-15

W-0

W-56

W-T1 W-14

W-17

W-239

P-14

W-224W

W-225

Locking Screw

HeatShieldScrews

CMABoard

Location

A

B C

Figure 8 — Access To The CMA Board

LED Fault Light ConditionsThe generator may have to run for long periods of timewith no operator present. For that reason, the CMA isequipped with sensing circuits that automatically shut downthe generator in the event of potentially damaging conditionssuch as low oil pressure, high oil temperature, over speed,and other conditions.

A light on the control panel (Figure 10), called theDiagnostic LED will flash on and off in a series of blinks. Theblink pattern is repeated with a brief pause between eachset.

The number of blinks in the series indicates the detectedfault. These conditions are listed on the control panel andbelow:

Number of LED Flashes Fault Description

1 Low Battery Voltage

2 Low Oil Pressure

3 Low Voltage

4 Engine Fail to Start

5 Low Frequency

6 Engine Overspeed

7 Oil Temperature High

Resetting The Fault DetectionSystem

An operator or technician must reset the fault detectionsystem each time it activates.

To do so:

• Place the AUTO/OFF/MANUAL switch in the OFFposition for 30 seconds or more.

• Place the AUTO/OFF/MANUAL switch in the AUTOposition.

If the fault is not corrected, it will be detected again and theunit will again go into Auto Shutdown with the same faultlight indication.

Trickle Charge OperationThe trickle charge circuit is a Float Charger Type and isdesigned to maintain the voltage of the battery. When utilityvoltage is present and the unit is switched to the AUTO orOFF position, the trickle charger will maintain the voltageof a fully charged battery. It will not recharge a dead battery.With the engine running, the trickle charge system is shutdown by the CMA and battery voltage is maintained by thegenerator battery charge winding.

Refer to the Control System Schematic on pages 56-57.Utility voltage is delivered from the fuses in the transferswitch through the terminal strip to the step-downtransformer with wires N1 and N2. From the transformer,24VAC is delivered to the CMA through Wires #224 and#225. The CMA rectifies this 24VAC to 12VDC. This isdelivered to the battery via Pin #12, Wire #15, through the15 Amp fuse, and on to the battery with Wire #13.

Fuel SupplyThe following fuel supplies are necessary to ensure effectivegenerator operation (Figure 11).

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ation

Figure 10 — Diagnostic LED

Figure 11 — Fuel Consumption Table

* = Natural Gas in cubic feet per hour

** = LP Vapor in gallons per hour/cubic feet per hour

Model Natural Gas* LP Vapor**1/2 Load Full Load 1/2 Load Full Load

1815(12kW) 102 195 41.03 78.63

17



Gen

eral

Info

rmat

ion

Figure 12 — Control Module & Switch Module Assemblies — Connector Pins, Functions & Wire Numbers for Model 1815

Control Module Assembly (CMA)Connector Pins, Functions & Wire Numbers

(As seen from wire side of connector in the generator)

Transfer Switch Module Assembly (TSMA)Connector Pins, Functions & Wire Numbers

(As seen from inside the transfer switch)

12VDC Input while A/O/M is in "AUTO"

12VDC Input while A/O/M is in "Manual"

Fuel Solenoid Valve & Hourmeter

Ignition Shut Down

12VDC to Starter Contactor

Not Used

Not Used

Low Oil Pressure Shut-down

Pulse Voltage to LED Lamp

Load Voltage (240VAC)

Transformer (24VAC)

Ground (GND)

12VDC Output for Trickle Charger (Battery Power)

"Set Exercise"

Crank Disconnect @ 20VAC

High Oil Temperature Shut-downP-18

P-17

P-16

P-14

P-11

P-12

P-13

P-10

P-7

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

P-15

W-241

W-224

W-225

W-T2

W-85

W-95

W-66

W-170

W-15

W-0

W-56

W-T1 W-14

W-17

W-239

J1

J2

J4

J5

J6

W-205

W-N1

W-N2

W-206

W-E2

W-E1

Transfer Switch "Utility" Coil

240VAC "Utility Sensing"

Transfer Switch "Stand-By" Coil

240VAC "Generator Sensing"

J3

GND - GroundP - Pin Number W - Wire Number A/O/M - AUTO/OFF/MANUAL

Uti

lity

Sen

sin

g

Uti

lity

Sen

sin

g

Terminal Board(As seen from inside the generator)

(As seen from inside the 100/200 transfer switch only)

18



General

Inform

ation

19

Model 1815 (12kW) Troubleshooting


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TROUBLESHOOTING INFORMATION

MODEL 1815 (12KW)

TROUBLESHOOTING LED FAULTS

Dead Unit / Low Battery Voltage: (No Blink [ ] / One Blink [ • ])

A unit with a completely depleted starting battery will notbe capable of powering the Diagnostic LED (no blink). Whenthe generator cannot start because the battery outputpower is below that needed to crank the engine, theDiagnostic LED will have an indication (one blink). Thecauses for either of these problems may be a failed battery,a parasitic drain on the battery or a failed trickle charger.The test and repair procedures for these three conditionsare outlined below.

Check Battery:

• Switch AUTO/OFF/MANUAL to OFF.

• Remove 15 Amp fuse.

• Disconnect battery cables.

Using the approved procedure for your battery tester,check the state of charge.

• Recharge battery, if required, and retest.

If battery replacement is required, use current BRIGGS & STRATTON recommended replacement part.

• Connect the battery cables.

• Reinstall the 15 Amp fuse.

Check Trickle Charging System:

NOTE: Depending on the state of charge of abattery, a slight (+) current flow indicates that thecharging system is working. (.033 Amp for a fullycharged battery to .612 Amp for a depleted battery)

Follow the recomendations of your meter’s instructionmanual.

• Install DC Amp meter between Negative (-) batteryterminal and Negative (-) battery cable.

•• If a (+) current flow is detected:

The trickle charge system is functioning.

• Connect Negative (-) battery cable.

• Reset the Fault Detection system

• Start unit.

•• If a zero or negative (-) Amp draw is detected:

Troubleshoot The Trickle Charging System:

NOTE: If the diode in the battery charge rectifiershorts, it will drain the battery to ground.Symptom: The battery charge resistor is warm,even when the unit isn’t or hasn’t been running.

• Repair and/or replace defective wiring or components.

• Remove 15 Amp fuse.

• Remove the (-) battery cable.

• Replace 15 Amp fuse.

With (+) battery cable removed, select AUTO at theAUTO/OFF/MANUAL switch.

• Measure for DC voltage at Pin #12, Wire #15, at theCMA and Ground (Figure 13).

20



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WARNING

• Ensure that generator circuit breaker is OPENbefore performing tests.

Follow battery safety rules.This unit may start any timethe AUTO/OFF/MANUAL isin the AUTO position.

CAUTION: Do not allow disconnected cablesto come in contact with ground during these tests.

21

should be measured.

•• If charging voltage at the CMA board is OK:

• Repair fuse, wiring and/or connections betweenPin #12, Wire #15 between the CMA and (+) batterycable.

• Recheck for charging voltage at (+) battery cable.

•• If trickle charge voltage (14VDC) is not at the CMAboard:

• Proceed with Stepdown Transformer Inspection.

Check The Step-down Transformer

• Measure for AC voltage across Pin #14, Wire #224 &Pin #15, Wire #225 at CMA (Figure 14).

should be measured

•• If 20-26VAC is present (going in) on Pins #14 & Pin #15, but 12VDC was not measured (coming out) at

Pin #12, Wire #15, with the AUTO/OFF/MANUALswitch set to OFF:

• Replace The CMA board.

•• If 20-26VAC is not at present at Pin #14 & #15:

• Measure AC voltage across N1 & N2 at the generatorterminal strip (Figure 15).

should be measured.

•• If 240VAC is present at N1 & N2 but 20-26VAC is notpresent at CMA:

• Repair and/or replace wiring, connectors or step-down transformer.

NOTE: Make sure to check the fuses in the transferswitch.



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Figure 13 — Measure Pin #12, Wire 15 at CMA

12-14VDC

20-26VAC

Verify that there are no other faults

BEFORE

replacing the CMA circuit board.

Verify Ground connection on CMA circuit board.

(See Figure 27)

P-18

P-17

P-16

P-14

P-11

P-13

P-10

P-7

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

P-15

W-241

W-224

W-225

W-T2

W-85

W-95

W-66

W-170

W-0

W-56

W-T1 W-14

W-17

W-239

P-12

W-15

P-18

P-17

P-16

P-11

P-12

P-13

P-10

P-7

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

W-241

W-T2

W-85

W-95

W-66

W-170

W-15

W-0

W-56

W-T1 W-14

W-17

W-239

P-14

W-224W

W-225

Figure 14 — Measure Pin #14 & #15 at CMA Board

Figure 15 — Measure across N1 & N2 in Generator

Approx. 240VAC

•• If 240VAC is not present at wires N1 & N2 in generator:

• Measure for 240VAC at UTILITY CONNECTION lugsin transfer switch (Figure 16).

should be measured.

•• If voltage is present at the transfer switch terminal strip:

• Repair wiring between generator and transfer switchterminal strips.

•• If no voltage is present at transfer switch terminal strip:

• Check fuses/wiring in transfer switch and repair orreplace as necessary.

• Reset the Fault Detection system by:

• Placing the AUTO/OFF/MANUAL switch in theOFF position for 30 seconds or more.

• Close the generator circuit breaker.


• Remove utility voltage and verify system operation.

• Reinstall all enclosure panels and return system tostandby configuration.

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

The generator unit is equipped with an oil pressure switch.The contacts of the switch are normally closed (NC) andare held open by engine oil pressure during operation.Should the engine oil pressure drop below 8 psi, the switchcontacts will close, creating a connection to ground and theengine will be shut down.

The following sequence of events takes place during the first10 second interval after engine startup:

- Oil PSI switch is normally closed (NC).

- CMA bypasses oil PSI switch during initial crank.

- Switch opens after engine has started and produces oilpressure.

- CMA senses engine is running by sensing frequency onPin #10, Wire #66.

- Once CMA senses engine is running, the CMA looksfor a ground on Wire #85.

- If ground is present on Wire #85, CMA will shut enginedown and the LED will flash in a set of two blinks.

To remedy a low oil pressure condition, fix any obvious oilleak and/or add the recommended oil to the FULL mark onthe dipstick.

• Reset the Fault Detection system as described earlier.

• Start the generator (No Load, as described on page 10).

If a low oil pressure condition still exists, the engine willstart and shut down after about 10 seconds and theDiagnostic LED will flash in a set of two blinks.

Low Oil Pressure Troubleshooting Procedure:

• Select OFF at the AUTO/OFF/MANUAL switch.


• Remove utility voltage

• Remove 18-pin connector from CMA

• Remove Wire #85 from oil PSI switch (Figure 17).

22



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Figure 16 — Measure across N1 & N2 in Transfer Switch

About 240VAC

23

• Measure for short-to-ground on Wire #85.

•• If a short is detected:

• Repair and/or replace wiring, as necessary.

•• If no short is detected:

• Remove oil pressure switch.

• Install oil pressure gauge.

• Re-install connector at CMA board.

• Re-install 15 Amp fuse.

• Turn utility ON.

• At the AUTO/OFF/MANUAL switch, selectMANUAL.

The engine should start and run.

NOTE: Oil Pressure @ 70° F (21° C): 10 ~ 50 PSI(0.7 ~ 3.5 Bar)

•• If oil pressure is low:

Refer to engine service manual for repair procedures.

•• If problem persists:

• Replace oil pressure switch.

•• If oil pressure is normal:

• Replace CMA.

• Replace the 15 Amp fuse.

• Close the generator circuit breaker.


• Remove utility power and verify system operation.

• Re-install all enclosure panels and return system toAutomatic standby configuration.

Low Voltage: (Three Blinks [ • • • ])

The Low Voltage shutdown is designed to protect thegenerator and its loads from an output voltage that is toolow. When utility power fails, the engine on the HomeGenerator System has started and the transfer switch hastransferred the loads to the generator, the CMA sensesoutput voltage at Pins #16 and #17 on wires T1 and T2(Refer to the schematic on pages 56-57). If the CMA doesnot sense generator voltage, it will shut down the generatorand the Diagnostic LED will blink in a set of three.

This condition may be caused by:

- A restriction in the fuel flow

- A broken or disconnected signal lead

- A failed alternator winding

- An open control panel circuit breaker

Low Voltage Troubleshooting Procedure:

Gain access to the generator unit by removing the air intakeand control panel doors and remove the cover to the backof the CMA board (See Page 15, Figure 8).

• Reset the fault indication LED by selecting OFF at theAUTO/OFF/MANUAL switch for 30+ seconds.

Ensure that the generator circuit breaker is in theCLOSED position and the 15 Amp fuse is installed andfunctional.

• Perform a manual start.

When the unit has stabilized, check the generator output:

• Measure the voltage at the input and output screws onthe back of the circuit breaker (Figure 18).



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Figure 17 — Measure Wire #85 from PSI Switch


BEFORE



(See Figure 27)

should be measured.

•• If there is no voltage on the input side of the breaker:

• See Checking The Rotor Winding on page 45.

Make sure the breaker is CLOSED.

•• If Input Voltage is OK at the breaker, but there is noOutput Voltage:

• Replace Circuit Breaker.

•• If voltage is present at both the input and output side ofthe circuit breaker:

• Make sure the sensing wires are attached to the outputside of the circuit breaker.

• Shut the unit down by selecting OFF at theAUTO/OFF/MANUAL switch.

• Gain access to the automatic transfer switch.

• Visually inspect the components for any sign ofelectrical failure and repair/replace any obvious faults.

Engine Fails To Start: (Four Blinks [ • • • • ])

This is a feature of the control module assembly (CMA) thatprevents the standby unit from damaging itself by continuallyattempting to start, in spite of a problem that is beyond theCMA's ability to monitor. Whenever the unit is directed tostart (MANUAL or AUTO), the CMA delivers 12VDC fromPin #5, Wire #56 to the starter contactor for 15 seconds. Itthen pauses for 15 seconds and repeats the attempt until 90seconds of start time have accumulated.

During the 15 second starting attempt, the CMAsimultaneously delivers 12VDC from Pin #7, Wire #14 tothe hour meter and fuel solenoids(s) while monitoring Pin#10, Wire #66 for a minimum frequency signal. Thisfrequency terminates the delivery of start voltage to thestarter contactor. If the minimum frequency signal has notbeen sensed after 90 accumulative seconds of start time, theCMA terminates the engine cranking cycle and triggers theLED to flash in a set of four blinks.

This directs the service technician to examine supportingsystems that could prevent the standby system fromoperating.

For example:

- No Fuel

- Fuel Solenoid Failure

- Fuel Supply Discrepancies

- Failed Starter Motor

- Failed Starter Motor Connections

- Engine Component Failures

- Clogged Engine Air Filter

- Loose Spark Plugs

- Failed and/or Damaged Wiring

- Clogged atmospheric vent.

Troubleshooting Procedure:


• Select MANUAL at the AUTO/OFF/MANUAL switch andobserve system operation.

Two possible conditions will exist;

Engine cranks but fails to start: (Page 25).

Engine fails to crank: (Go to page 28).

24



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Figure 18 — Measure Output Voltage of Generator

about 240VAC

25

Engine Cranks But Fails To Start:

Ensure that adequate fuel is available to operate the standbysystem.

• Inspect the fuel supply tank to verify that the main supplyvalve is open.

• Inspect fuel supply plumbing for any shut-off valves thatmay be closed.

NOTE: Fuel shut-off valves are often installed as adiscretionary convenience to the owner. Therefore,the number of shut-off valves may vary with thecircumstances of each installation. Be sure to tracethe entire fuel supply system.

• Correct any fuel supply problems.


• Select MANUAL at the AUTO/OFF/MANUAL switch andobserve system operation.

•• If no fuel supply discrepancies are present, and enginecranks but fails to start:

• Remove the four access panels to the generator unit.

Inspect the standby unit for any obvious broken orcorroded electrical connections. Starting at the controlpanel, visually inspect wiring and terminals associated withthe following components:

- Oil Pressure and Oil Temperature _____

- # 1 Spark Plug Lead _____

• Remove the plug lead and check that the plug is tight in the engine. _____

- Starter Contactor _____

- Fuel Solenoid _____

- Generator and Engine Grounds _____

- Starter Motor _____

- # 2 Spark Plug Lead _____

• Remove the plug lead and check that the plug is tight in the engine. _____

Gain access to the control module assembly by removingthe CMA safety panel (Figure 8 on page 15).

- Terminal board _____

- All component connections _____

- 18-Pin connector on the CMA board. _____

Repair and/or replace any damaged wiring or terminalconnections.

• Reset LED, attempt MANUAL start and observe systemoperation.

•• If there are no obvious electrical faults, and the problempersists:

Verify that fuel pressure is available to the fuel solenoid.

• Install a manometer, as illustrated in figure 19.

should be measured.



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WARNING

• Use caution to avoid personal electrical shock ordamage to the system.

Utility voltage is presentbehind the CMA safety panel.

Figure 19 — Temporary Manometer Installation

11 to 14 inches of water (in. W.C.) - LP

5 to 7 inches of water (in. W.C.) - NG

•• If the proper fuel pressure is not present:

• Repair and/or replace fuel delivery system.

• Re-test fuel pressure as described above.

•• If fuel pressure is acceptable:

Check the Fuel Solenoid.

While the engine is cranking:

• Check for DC voltage at the fuel solenoid (Figure 20).

should be measured.

•• If no voltage is present at the fuel solenoid:

• Check for voltage at Pin #7, Wire #14 at the CMAharness connector (Figure 21).

should be measured.

•• If no voltage is present:

• Replace the CMA Circuit Board.

•• If voltage is present at the solenoid:

The fuel solenoid delivers fuel pressure to the fuel regulator.The regulator delivers fuel to the carburetor when anegative pressure is created by the intake stroke of theengine pistons. If fuel and fuel flow are present withoutignition, the gas must be expelled through the exhaust pipe.

Gas Regulator

The gas regulator is an atmospheric zero governor whichacts like the float and needle valve in a gasoline carburetor.Air flow through the venturi in the carburetor creates avacuum which acts through an internal outlet on thediaphragm.

26



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Figure 20 — Check Fuel Solenoid for DC Voltage

7-12VDC

Figure 21 — Check Pin #7, Wire #14 at CMA Connector

7-14VDC


BEFORE



(See Figure 27)

P-18

P-17

P-16

P-14

P-11

P-12

P-13

P-10

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

P-15

W-241

W-224

W-225

W-T2

W-85

W-95

W-66

W-170

W-15

W-0

W-56

W-T1

W-17

W-239

P-7

W-14

27

Atmospheric pressure then forces the diaphragm toward thevacuum, depressing the lever and pulling the valve seat awayfrom the orifice which allows fuel to flow, as long as thedemand persists. When the vacuum ceases, a spring forcepushes on the lever and forces the valve seat against theorifice -shutting off the fuel flow.

NOTE: Fuel should not flow through the gasregulator when the engine is not running.

The easiest way to check the mechanical operation of thefuel solenoid and the fuel regulator is to smell the exhaustduring the starting sequence.

•• If fuel is detected, proceed to Check Ignition Spark onpage 28.

•• If no indication of fuel is detected at the exhaust pipeduring the starting sequence:

Check the fuel solenoid and/or fuel regulator for evidence ofmechanical failure.

• Remove the pipe plug that caps the regulator test portand install a manometer (Figure 22).

should be measured while thefuel solenoid is activated.

•• If no fuel pressure is measured:

• Replace the fuel solenoid.

•• If fuel pressure is measured:

Refer to figure 23 for the following procedure.

The fuel regulator has one atmospheric vent that balancesdiaphram pressures.

• Install a 1/8 NPT barb fitting that has a 2 ft. length ofhose attached to it.

• Plug the other vent hole.

• Gently blow into the hose.

While the fuel solenoid is energized, this pressure will allowfuel to pass through the regulator. This fuel flow will beindicated on the manometer as a decrease in pressure.

•• If no fuel flow is detected:

• Replace the fuel regulator.

•• If fuel flow is detected:

• Refer to the BRIGGS & STRATTON Engine ServiceManual to determine the condition of the gaseous fuelcarburetor.



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DANGER

Extinguish all sources of fireand do not smoke whileperforming this inspection.

Figure 22 — Fuel Regulator with Manometer Installed

NG = 5 to 7 (in. W.C.)

LP = 11 to 14 (in. W.C.)

Figure 23 — Testing the Fuel Regulator

CAUTION: Do not use compressed air. Theregulator diaphram is easily ruptured.

Check Ignition Spark:

• Turn off the manual fuel valve that is located on theoutside of the building.

• Refer to the Briggs & Stratton Engine Service Manual todetermine the proper method for checking the enginefor ignition spark.

Engine Fails to Crank:

Check the 15 Amp fuse.

• Remove the control panel door

• Inspect 15 Amp fuse, reinstall or replace.

•• If fuse was replaced, reset LED:


• Attempt MANUAL start and observe systemoperation.

.•• If the fuse is OK:

Check the starter contactor.

• OPEN the generator circuit breaker.

• Reset LED.

• Gain access to the starter contactor by removing thebattery door.

Select the MANUAL position of the AUTO/OFF/MANUALswitch and while the engine start cycle is in progress:

• Measure for a voltage at the coil terminals of thestarter contactor, as shown in figure 24.

should be measured.

NOTE: Remember that the CMA only delivers12VDC to the starter contactor for 15 seconds andthen rests for 15 seconds.

•• If no voltage is present at the coil terminals of the startercontactor:

Gain access to the CMA circuit board by removing the airintake door and the CMA safety panel (Page 15, Figure 8).

• Measure the voltage at Pin #5, Wire #56 to ground, asshown in figure 25.

should be measured while cranking.

•• If no voltage is measured:

• Replace the CMA circuit board.

•• If 9-14VDC is present at the starter contactor:

• Measure the voltage at the starter, as shown in figure 26.

28



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Figure 24 — Measuring Coil Terminals of Starter Contactor

7-14VDC

Figure 25 — Measure Pin #5, Wire #56 at the CMA

9-14VDC


BEFORE



(See Figure 27)

P-18

P-17

P-16

P-14

P-11

P-12

P-13

P-10

P-7

P-8

P-9

P-4

P-6

P-1

P-2

P-3

P-15

W-241

W-224

W-225

W-T2

W-85

W-95

W-66

W-170

W-15

W-0

W-T1 W-14

W-17

W-239

P-5

W-56

29

should be measured at the starter terminaland ground during the period that the CMAdelivers 12VDC to the terminals of the startercontactor.

•• If voltage is present but the starter won’t engage:

• Check the engine grounding cable for good contact.

Repair or replace any defects with the grounding cable.

If no voltage is present at the starter terminal:

• Replace the starter contactor.

•• If starting voltage is present at the starter terminal:

• Refer to the BRIGGS & STRATTON Service Manual forprocedures to check the engine starter.

Low Frequency: (Five Blinks [ • • • • • ])

The low frequency shutdown feature is designed to protectthe generator and the devices connected to the protectedcircuits from an output frequency that is too low. The CMAsenses a frequency of 60 Hz at Pin #10, Wire #66. If outputfrequency drops below a minimum for more than a fewseconds, the CMA will shut down the generator and triggerthe diagnostic LED to blink in a set of five blinks.

This condition may be caused by a failed engine governor orby excessive loads on the protected circuits of the house.

Low Frequency Troubleshooting Procedure:

Verify that the Control Module Assembly (CMA) isgrounded.

• Check for continuity between Pin #13, Wire #0 andGround as shown in figure 27.

•• If no continuity is measured:

• Repair and/or replace any defective wiring or terminals.

• Retest continuity between Pin #13, Wire #0 andGround as shown in figure 27.

•• If continuity is measured:

• Install a jumper wire between Wire #15 at the fuseholder and Wire #14 at the hour meter as illustrated infigure 28.



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Figure 26 — Measure Starting Voltage

7-14VDC

Check engine RPM.

• Set engine RPM to3600, as specified inthe BRIGGS &STRATTON engineservice manual.

DIGITAL TACH & HOURMETER

63600

Tiny-Tach

Clamp on Spark Plug Wire

BRIGGS & STRATTON #19389

3600

Figure 27 — Continuity at Pin #13, Wire #0 and Ground

P-18

P-17

P-16

P-14

P-11

P-12

P-10

P-7

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

P-15

W-241

W-224

W-225

W-T2

W-85

W-95

W-66

W-170

W-15

W-56

W-T1 W-14

W-17

W-239

P-13

W-0

• Select MANUAL at the AUTO/OFF/MANUAL switchand allow engine to start and stabilize.

• Measure voltage and frequency at Pin #10, Wire #66and Ground as shown in figure 29.

should be measured.

NOTE: Follow the Frequency Measurementinstructions that apply to the type of meter you areusing.

•• If frequency and voltage are correct:

• Replace CMA Circuit Board.

•• If frequency is not correct:

Check engine RPM.

• Set engine RPM to 3600, as specified in the BRIGGS &STRATTON engine service manual.

•• If voltage is not correct:

While the engine is running;

• Measure voltage and frequency at Wire #66 andWire #77 as shown in figure 30.

should be measured.

•• If no output voltage is measured:

• Check for open Battery Charge Winding (BCW)(Refer to Checking The Battery Charge Winding onpage 45.

• Repair or replace as necessary.

30



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Figure 28 — Jump Wire #15 at Fuse & #14 at Hourmeter

Figure 29 — Voltage & Frequency at Pin #10, Wire 66 & Ground

18-22VAC @ 60-62Hz

P-18

P-17

P-16

P-14

P-11

P-12

P-13

P-7

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

P-15

W-241

W-224

W-225

W-T2

W-85

W-95

W-170

W-15

W-0

W-56

W-T1 W-14

W-17

W-239

P-10

W-66

Figure 30 — Voltage & Frequency at Wire #66 & Wire #77

18-22VAC & 60-62 Hz


BEFORE



(See Figure 32)

DANGER

• The only way to stop the engine is to remove thejumper wire.

This jumper will energize thefuel solenoid and allow theengine to run for testingpurposes.

31

•• If 18VAC is measured while the engine is running:

• Measure the output from the battery charge rectifierbetween Wires #66 and Wire #0 as shown in figure 31.

should be measured.

•• If 18-22VAC is not measured:

• Check/test for open resistor.

•• If Resistor is OK:

• Check for open/faulty wiring.

Repair as necessary and retest.

Over Speed: (Six Blinks [ • • • • • • ])

This feature of the Home Generator System protectsdevices that are wired into the protected circuits by shuttingdown the generator if it runs faster than the governed RPMlimit (3600 RPM).

The control module assembly (CMA) senses frequencyoutput at Pin #10, Wire #66.

If the generator output frequency (directly proportional toengine RPM) gradually increases from 60 Hz and exceeds 72Hz for five seconds, the CMA shuts the generator down anddirects the fault indication LED to flash in a set of six blinks.

If the generator output frequency exceeds 75 Hz, the CMAshuts the generator down instantly and initiates the faultindication LED to flash in a set of six blinks.

The reason for this latitude in sensing output frequency isthat often a governor will hunt for the desired setting. Thiscauses variable frequency outputs that are not harmful untilthey reach the 72 Hz limit. Should the governor failcompletely, the RPM will increase uncontrolled. In this case,the generator will appear to stall immediately after starting.In reality, it is shut down when the output frequencyreaches 75 Hz.

Over Frequency Troubleshooting Procedure:

Verify that the Control Module Assembly (CMA) isgrounded.

• Check for continuity between Pin #13, Wire #0 andground as shown in figure 32.

•• If no continuity is measured:

• Repair and/or replace any defective wiring or terminals.

• Retest continuity between Pin #13, Wire #0 andground as shown in figure 32.



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Figure 31 — Measure Output from Battery Charge Resistor

18-22VAC & 60-62 Hz

Check engine RPM.

• Set engine RPM to3600, as specified inthe BRIGGS &STRATTON engineservice manual.

DIGITAL TACH & HOURMETER

3600

Tiny-Tach

Clamp on Spark Plug Wire

BRIGGS & STRATTON #19389

3600

Figure 32 — Continuity at Pin #13, Wire #0 & Ground

P-18

P-17

P-16

P-14

P-11

P-12

P-10

P-7

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

P-15

W-241

W-224

W-225

W-T2

W-85

W-95

W-66

W-170

W-15

W-56

W-T1 W-14

W-17

W-239

P-13

W-0

•• If continuity is measured:

• Select MANUAL at the AUTO/OFF/MANUAL switchand allow engine to stabilize.

• Measure voltage and frequency at Pin #10, Wire #66and Ground as shown in figure 33.

should be measured.

NOTE: Follow the Frequency Measurementinstructions that apply to the type of meter you areusing.

•• If frequency and voltage are correct:

• Verify that CMA is not picking up a signal elsewhere.

• Replace CMA Circuit Board.

•• If frequency is not correct:

Check engine RPM.

• Set engine RPM to 3600, as specified in the BRIGGS &STRATTON engine service manual.

High Oil Temperature: (Seven Blinks [ • • • • • • •])

The contacts of the temperature switch are normally open(NO). If the engine oil temperature exceeds approximately140°C (284°F), the switch contacts close and the engineshuts down.

Common causes for this condition include:

- Running the unit with all access doors removed

- Obstructed air inlet or exhaust port

- Debris in the engine cylinder cooling fins

When the problem is corrected, reset the fault detectionsystem:


High Oil Temperature Troubleshooting Procedure:

• Remove Wire #95 from the Oil Temperature Sensor asshown in figure 34.

• Start engine.

•• If engine starts and runs:

• Verify engine is not overheating.

This can be accomplished by checking the following:

• Verify that the cooling intake is clear of obstructions.

• Check that the engine has the proper amount and typeof oil.

• See that the engine cooling fins are not clogged.

32



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18-22VAC & 60-62 Hz

P-18

P-17

P-16

P-14

P-11

P-12

P-13

P-7

P-8

P-9

P-4

P-5

P-6

P-1

P-2

P-3

P-15

W-241

W-224

W-225

W-T2

W-85

W-95

W-170

W-15

W-0

W-56

W-T1 W-14

W-17

W-239

P-10

W-66

Figure 33 — VAC & Hz at Pin #10, Wire #66 & Ground


BEFORE



(See Figure 32)

Figure 34 — Remove Wire #95 from Temp. Sensor

Make Sure Wire #95 DoesNot Touch Ground

33

• Check that all ducting, gaskets, shrouding and enclosurepanels are in place.

NOTE: With more than two access doorsremoved, the engine will run hotter than designed.

• Replace defective oil temperature switch.

•• If engine starts but won’t run:

• Select OFF at the AUTO/OFF/MANUAL switch.


• Remove utility power

• Remove 18-pin connector from CMA

• Measure for short-to-ground on Wire #95, as shown infigure 35.

•• If a short-to-ground is measured:

• Repair and/or replace wiring as necessary.

•• If no short-to-ground is measured:

• Replace CMA circuit board.



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Figure 35 — Measure Short-To-Ground at Wire #95


BEFORE



(See Figure 32)

34



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35


GENERATOR ASSEMBLY

MODEL 1815 (12KW)

Model 1815 (12kW) Generator Assembly

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SPECIFICATIONS: Model 1815(CHGEN12000)

Generator

Rated Maximum Power (LP*) 12 kW

Rated Maximum Load Current:

at 240 Volts 50.0 Amps

at 120 Volts 100 Amps

Rated AC Voltage 120/240 Volts

Rated Frequency 60 Hz at 3600 RPM

50 Hz at 3000 RPM

Phase Single Phase

Power Factor 1.0

NG Fuel Supply Pressure 5-7 in. W.C. (127-356mm)

LP Fuel Supply Pressure 11-14 in. W.C. (279-356mm)

Normal Operating Range -20°F (-28.8°C)-104°F (40°C)

Output Sound Level 69dBa@23ft. (7m) at full load

* Natural gas rating will depend on specific fuel but typical derates are between 10% to 20% off the LP gasrating.

Engine

Type Air Cooled, 4 Stroke, V-Twin, Horizontal Shaft, OHV Dual Fuel Engine

Bore x Stroke 2.97 (75mm) x 2.75 (70mm)

Displacement 627cc

Spark Plug BRIGGS & STRATTON # 496018

Oil Type Synthetic ILSAC GF-2 API

“SJ/CF ENERGY CONSERVING

Oil Capacity (w/filter) 56 fl. oz. (1.66L)

Spark Plug gap 0.030 in (.76mm)

37



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Figure 36 — Model 1815 12kW

Engine Maintenance

Check fuel lines and fittings frequently for cracks or leaks.Replace if necessary.

Checking Oil Level

Before placing the standby generator in service and at therecommended maintenance interval, check the engine oillevel, as follows:

• Remove Oil Service door. Clean area around oil fill anddipstick locations.

• Remove dipstick. Wipe with clean cloth.

• Insert dipstick fully. Remove and check oil level.

• If oil level is low, remove oil fill cap and slowly addrecommended oil to bring level to “Full” mark ondipstick.

• A reusable oil spout that fits most oil bottles is suppliedto make it easier to pour oil into the engine.

Changing the Oil and Oil FilterOil capacity is approximately 1-1/2 quarts (48 ouncesor 1.6 liters) when changing oil and filter. Use only5W-30 API Service Grade SJ or greater synthetic oil.

Change oil after every 50 operating hours

Replace oil filter every 100 operating hours

If you are using this engine under dirty or dusty conditionsor in extremely hot weather, change the oil more often.

Use the following instructions to change the oil while theengine is still warm:

• Unclip and wipe the oil drain hose clean with a rag.Place the oil drain hose into a suitable container. Graspthe oil drain fitting and push it in towards the engine.Rotate it counterclockWise to its stop and pull thefitting outwards. Oil should begin to flow out of the oildrain hose.

• After the oil is drained, grasp the oil drain fitting androtate it clockWise until it locks in place. Position theoil drain hose in its storage clip.

• Place a suitable container beneath the oil filter andremove the filter.

• Coat the o-ring of the new filter with fresh clean engineoil. Turn the new filter clockWise by hand until thegasket contacts the filter adapter, then tighten 1/2 to3/4 turn more.

• Fill engine with oil as described above.

• Install and tighten the oil fill cap.

• Run the engine for a minute, stop the engine and checkfor oil leakage around the oil filter. Recheck oil level.

Replacing the Spark Plugs

Replace the plugs every year. Use the recommended sparkplugs gapped for 0.030 in. (0.76 mm).

• Stop the engine and pull the spark plug wires off of thespark plugs.

• Clean around the spark plugs and remove them fromthe cylinder head.

• Clean off carbon deposits on the spark plug electrodeusing a wire brush or commercial solvent. Do not blastclean.

• Set the plug gap as recommended. Install the correctlygapped spark plugs into the cylinder heads. Torque to 15 lb. ft.

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DANGER

• This will prevent accidental engine start.

Remove 15 Amp fuse fromcontrol panel. Disconnect

spark plug wires from sparkplugs.

39

Service Air Cleaner

The engine’s air cleaner is one of the most important areasto maintain. The engine will not run properly and will bedamaged if it is run with a dirty air cleaner system.

Use only genuine BRIGGS & STRATTON parts or theirequivalent. The use of replacement parts which are not ofequivalent quality may damage the engine.

Clean the foam precleaner every 25 hours and the cartridgeevery 100 hours of operation.

Clean or replace more often in dusty or dirty conditions.

To service the air cleaner components:

• Unhook clips on both sides of air cleaner cover andremove.

• Carefully slide foam precleaner off cartridge.

• To service precleaner, wash in liquid detergent andwater. Squeeze dry in a clean cloth. Never twist!Replace if very dirty or damaged.

• Remove knob and plate. Carefully remove cartridge toprevent debris from entering carburetor.

• To service cartridge, clean by tapping gently on a flatsurface. Do not oil cartridge. Replace if very dirty ordamaged.

NOTE: Do not use petroleum solvents, e.g.kerosene, which will cause the cartridge todeteriorate. Do not use pressurized air to cleancartridge. Pressurized air can damage the cartridge.

• Reinstall cartridge, plate and knob.

• Reassemble precleaner on cartridge.

• Replace cover and attach clips to body.

Inspect Spark Arrester Screen

The engine exhaust muffler has a spark arrester screen.Inspect the screen every 50 hours of operation or onceeach year, whichever comes first. The spark arrester mustbe maintained in good condition by the owner/operator.

Inspect the spark arrester as follows:

• Using a powerful flashlight, examine the circular screeninstalled in the end of the exhaust port. There shouldbe no rips or tears in the screen. There should be littleor no accumulated soot on the screen.

• Replace the screen if torn, perforated or otherwisedamaged. Do not use a defective screen. ConsultBRIGGS & STRATTON Technical Services forassistance in changing the screen.

•• If screen is not damaged:

• It may be cleaned in place with a gentle brushing using awire brush or bottle brush.

Engine Governed Speed

CHANGING THE ENGINE GOVERNED SPEEDWILL VOID THE ENGINE WARRANTY AND

WILL ADVERSELY AFFECT SYSTEMOPERATION.

To assure smooth operation, keep governor linkage, springsand controls free of debris.

Valve Lash

Valve lash must be checked while engine is cold after every100 hours of operation. Adjust if necessary. Valve lash is:

Intake and Exhaust 0.004 - 0.006 in. (0.10 - 0.15 mm)

Carburetor Adjustments

The engine carburetor is preset at the factory. Thecarburetor should not be tampered with because doing sowill void the emission control system warranty. If youexperience problems or your engine is used at an altitudehigher than 5,000 feet, contact your installer or the factory.



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CAUTION: Never run this equipmentwithout the complete air cleaner system installedon the engine. Failure to do so will result inpremature engine wear and significantly reducedengine life.

CAUTION: The engine speed was properlyadjusted at the factory and should require noadditional adjustment. Do not attempt to changeengine speed. If you believe the engine is runningtoo fast or too slow, contact the factory forassistance.

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Engine Adjustment

It is commonly known that there are regional variances inthe combustibility of natural gas. Each standby unit isadjusted at the factory for correct NG operation. If thegenerator output voltage or frequency measured duringinitial Electrical Check (Page 11) is outside the listed ranges,the combustibility of the gas supplied at the installation sitemay be substantially different.

To adjust the engine for these regional variances, proceed asfollows;

• Remove the Air Intake and Control Panel access door.

• Remove the three M5 sheet metal screws that hold theCMA cover to the air intake guard (Figure 37).

• The mixture adjustment screw is shown in figure 38A.

• Connect an accurate frequency meter to the load sideof the main circuit breaker (on the back side of thecontrol panel).

• Ensure that the 15 Amp fuse is installed.

• Set the generator’s main circuit breaker to ON.

• Set the AUTO/OFF/MANUAL switch to MANUAL.When the engine starts, allow it warm up for twominutes.

• Normal no-load frequency is 62.0 to 62.5 Hz. Ifadjustment is needed at no-load, slowly rotate thegovernor adjustment nut (Figure 38B) clockwise and/orcounterclockwise until frequency is 62.0 to 62.5 Hz.

• Turn the service disconnet to the transfer switch OFF.The transfer switch will connect to the generator aftera short time delay.

• Load generator to rated Natural Gas rating.

• Connect an accurate frequency meter to the load sideof the main circuit breaker (on the back of the controlpanel). Frequency should be above 57.0 Hz.

• If frequency is below 57.0 Hz, slowly rotate thegovernor adjustment nut (Figure 38) clockwise and/orcounterclockwise until frequency is above 57.0 Hz.

• Reinstall the access hole plug.

• Turn the service disconnect to the transfer switch toON. The transfer switch will connect to utility powerafter a short time delay.


• After the engine has stopped, reinatall the air intakeguard.

• Reinatall the CMA cover to the air intake guard.

• Reinstall the air intake access panel.


NOTE: The mixture adjustment screw is the brassslotted screw in the center of the aluminum bossdirectly visible in the access hole.

40



Figure 37 — Accessing Engine Mixture Control

Air Intake Guard

CMACover

RemoveAccess

Hole Plug

Figure 38 — Engine Mixture Access & Adjustment Nut

A B

41



Figure 39 — Typical Wiring Diagram for Model 1815 Home Generator System with a 200 Amp Transfer Switch (CHGEN200ATSR)

Gnd

Neutral

Uti

lity

Sen

sing

Red

J4J5J6

J1J2J3

Green

NC1

(Utility)

NC1

NC2

NC2

(Generator)

GndNeut

Uti

lity

Sen

sing

Model Unit Part No.

Part No. DPE BCW

Ohms

Power

1815-0 12kW 192971GS

192969GS 1.30 0.027

4.67/4.67

.109/.109

Rotor Resistance ± 5%

Stator Resistance ± 5%

System InterconnectionsThe Home Stand-by System circuit interconnections consist of "Utility Supply" from the service disconnect to transferswitch, "Generator" supply leads to transfer switch, service panel leads to transfer switch and "Utility 240VAC" fromtransfer switch. All leads must be routed in conduit.

• The "Utility 240VAC" leads deliver utility power to generator circuit board.

The wiring diagram shown in figure 39 depicts the 200 Amp transfer switch. The same wiring procedure is used with the100 Amp transfer switch with the exception of the large grounding terminal for the neutral wire. In all other respects thewiring of the 100 Amp and 200 Amp transfer switches is identical. Additional wiring diagrams are given in the appendixstarting on page 55.

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Utility PowerSupply fromService Disconnect

12kW Rotor & Stator Resistance Values

42


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12kW Circuit Test IntroductionThe troubleshooting section of this service manual containspage references to inspection procedures of specificgenerator components. These components are related tothe various LED fault light indications. To gain access tosome of these components, it is necessary to disassemblesections of the generator enclosure.

This section is organized for the 12kW generator by "easeof access" to the various components with the easiestoperations given first and the more complex operationsfollowing.

In order of complexity, they include the following:

Operation: Page: Access Requirements: Page:

• Checking The Stator Power Winding Through The Harness 43 Access To CMA Board 15

• Checking The Battery Charge Winding (BCW) Through The Harness 43 Access To CMA Board 15

• Checking The Excitation Circuit 44 Roof Removal 47Muffler Box Removal 47Fuel Line from Regulator Removal 48

• Checking the Stator Power Winding 44 Roof Removal 47Muffler Box Removal 47Fuel Line from Regulator Removal 48

• Checking The Battery Charge Winding (BCW) 45 Roof removal 47Muffler Box Removal 47Fuel Line from Regulator Removal 48

• Checking The Rotor Winding 45 Roof Removal 47Muffler Box Removal 47Fuel Line from Regulator Removal 48Alternator Bulkhead Removal 49

• Removing The Meccalte-Generator 47 Roof Removal 47Muffler Box Removal 47Fuel Line From Regulator Removal 48Alternator Bulkhead Removal 49

43

Checking The Stator Power WindingThrough The Harness

Access Requirements:

• Access to CMA Board (Page 15)

Related Fault Indications:

• Low Voltage ([ • • • ]) Three Blinks

Checking the power winding resistance through the harness(as shown in figure 40A & B) ensures the integrity of thewinding and the associated wiring.

• Turn the generator circuit breaker “OFF”.

• Check between Wire #11 and Wire #22 orNEUTRAL.

• Check between Wire #44 and Wire #22 orNEUTRAL.

should be measured.

NOTE: Measuring through the harness will notverify a defective power winding but it will validate awinding/wiring combination that is serviceable.

To isolate the power winding:

See "Checking The Stator Power Winding" (Page 44).

Checking The Battery ChargeWinding (BCW) Through The Harness


• Access to CMA Board (Page 15)

Related Fault Indication:

• Low Battery Voltage ([ • ]) One Blink

Checking the battery charge winding resistance (BCW)through the harness (as shown in figure 41) ensures theintegrity of the winding and the associated wiring.

• Disconnect Wire #77 from the resistor and check toWire #66.

should be measured

NOTE: Measuring through the harness will notverify a defective battery charge winding (BCW) butit will validate a winding/wiring combination that isserviceable.

To isolate the battery charge winding:

See "Checking The Battery Charge Winding (BCW)"(Page 45).

Figure 40 — Checking Power Winding & Wiring Harness

.109 / .109 Ohms +- 5%

Figure 41 — Checking the BCW & Wiring Harness

0.027 Ohms +- 5%A B



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44


Replace Stator

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Checking The Excitation CircuitAccess Requirements:

• Roof Removal Page 47

• Muffler Box Removal Page 47

• Fuel Line From Regulator Removal Page 48



Gain access to the capacitors as mentioned above.

• Isolate The Capacitors

NOTE: Use the manufacturer's instructions thatapply to the type of meter you are using. The ratedcapacity is printed on the capacitors.

•• If a value discrepency is found:

• Replace Capacitor

Check Excitation Winding (DPE) Resistance between wiresthat were disconnected from capacitors and lead into thestator, as shown in figure 42.

should be measured.

•• If not:

• Check for short-to-ground.

•• If none:

See ”Removing The Meccalte-Generator” (Page 47).

•• If resistance reading is OK:

• Re-install/replace the capacitors

• Re-assemble the standby generator enclosure.

Checking The Stator Power WindingAccess Requirements:






Gain access to the stator power winding leads as mentionedabove.

• Isolate the colored wires from the terminal block.

• Measure the resistance value of the stator powerwinding as shown in figure 43.

should be measured.

•• If not:


•• If none:

Figure 42 — Checking Excitation (DPE) Winding Resistance

1.30 Ohms +- 5%

Replace Stator

.109 / .109 Ohms +- 5%

Figure 43 — Measuring Power Winding Resistance

45



• Check for defective lead wire between terminal blockand circuit breaker.


Checking The Battery ChargeWinding (BCW)






• Dead Unit ([ ]) No Blink

• Low Battery Voltage ([ • ]) One Blink

Gain access to the battery charge winding leads asmentioned above.

• Disconnect Wire #66 and Wire #77 from the Brownwires, on the terminal block.

NOTE: Always check individual windings toground.

• Measure the resistance value of the battery chargewinding as shown in figure 44.

should be measured.

•• If not:


•• If none:



• Check for a defective lead wire in the harness.


Checking The Rotor WindingAccess Requirements:




• Alternator Bulkhead Removal Page 49



Gain access to the rotor winding leads as mentioned above.

Figure 44 — Checking Battery Charge (BCW) Winding

0.027 Ohms +- 5%

Replace Stator



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NOTE: The rotor cannot be thoroughly inspectedwithout removing it from the generator assembly. Inaddition, detailed components of the rotor must bede-soldered in order to determine its servicability.Specific instructions as well as general informationabout this procedure is given at the end of”Removing The Meccalte-Generator” on page 47.

• Measure the resistance value of the rotor windings andcompare values to chart on page 41.

should be measured.

•• If not:


•• If none:



In order to assist you in performing electrical checks, unitreassembly and general troubleshooting, a reference of thegenerator terminal block is provided in figure 45.

4.67 / 4.67 Ohms +- 5%

Replace Rotor

Figure 45 — Generator Terminal Block Wiring

47

Removing The Meccalte-GeneratorRoof Removal

The roof is secured to the “Standby” enclosure with fournuts that thread on studs welded to the structure of theroof, as shown in figure 46.

• Remove the nuts and hardware shown above.

• Lift the roof from the enclosure.

Muffler Box Removal

To gain sufficient clearance to extract the muffler box it isnecessary to remove the the exhaust grill panel.

• Remove the four mounting screws that secure theexhaust grill to the enclosure. One side of the grill isshown in figure 47.

The muffler itself is supported by four metal brackets. Thesebrackets bolt to flanges that have been welded to themuffler and fit over four machine screws that secure themetal cover on top of the generator housing. Two bracketsare shown in figure 48.

• Remove the four brackets and retain the hardware.

NOTE: All four brackets must be removed.

CAUTION: Before enclosure disassembly:• Turn Switch “OFF”• Turn Fuel “OFF”• Remove 15 Amp Fuse

Figure 46 — Nuts That Secure Roof To HGS Enclosure

Figure 48 — Muffler Support Brackets (12kW)



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Figure 47 — Exhaust Grill Mounting Hardware

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Fuel Line From Regulator Removal

The fuel line passes through a hole in the bulkhead andconnects to a fitting on top of the regulator, as shown infigure 49A & B.

• Loosen the clamp that secures the hose to the fitting.

• Disconnect the hose, cover end to prevent dirtingestion and position out of the way.

• Remove the deflector that is mounted on the upperportion of the muffler box (Figure 50).

The muffler box is a two piece assembly that is secured tothe bulkhead with five self-tapping sheet metal screws(Figure 51).

• Remove the five screws that secure the upper portionof the muffler box to the alternator bulkhead.

• Remove the scews that hold the upper portion of themuffler box to the lower portion (Figure 52).

• Slide the upper portion of the muffler box out of theend of the enclosure.

• Remove the three remaining screws that secure thelower portion of the muffler box to the bulkhead andset the bottom of the muffler box aside.

Figure 51 — Muffler Box Supporting Hardware (12kW)

Figure 52 — Lower Muffler Box Screws

Figure 49 — Fuel Line Connection to Regulator

A B

Figure 50 — Muffler Box Deflector

49

This procedure allows you access (Figure 53) to thefollowing tests of the generator:

• Checking the Excitation Circuit (Page 44).

• Checking the Stator Power Winding (Page 44).

• Checking the Battery Charge Winding (Page 45).

Alternator Bulkhead Removal

The alternator bulkhead must be removed in order to:

• Check or replace the Rotor Assembly.

• Replace the Stator Assembly or the complete Meccalte-Generator

The following procedure outlines the necessary stepsrequired to gain access to the Meccalte-Generator as acomplete assembly.

• Using a 3/8" socket and ratchet, remove both headerbrackets as shown in figure 54A, B & C.

When these brackets have been removed:

• Disconnect cables from the battery, being careful toremove the negative (-) cable first.

• Remove the bolts that secures the battery clamp, asshown in figure 55.

• Remove Wire #16, Wire #13 and Wire #56 from theStarter Contactor as shown in figure 56.

• Retain all hardware.

Figure 55 — Battery & Mounting Hardware

Figure 56 — Wire #s 16, #13 and #56


Figure 54 — Header Bracket and Mounting Hardware

A

B C

Header BracketHardwareLocation

HardwareLocation


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Figure 53 — Generator Cover Removed

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• Remove Wire #14, which is ganged to the fuel shut-offsolenoid. See Figure 57.

• Gather the wires in the harness and work themthrough the hole in the alternator bulkhead as shown infigure 58.

• Ensure that all the wires in the harness are clear of thebulkhead.

• Make sure that the fuel hose is clear of the bulkhead.

• Remove the fuel supply from source at nipple on fuelsolenoid.

At this point, the alternator bulkhead is held to themounting base with seven 1/4" self-tapping screws asillustrated in figure 59.

• Remove these fasteners.

• Carefully lift the alternator bulkhead from the standbyenclosure (Figure 60).

Figure 58 — Wire Harness through Bulkhead

Figure 59 — Screws Holding the Alternator Bulkhead

Figure 60 — Removing Alternator Bulkhead

Figure 57 — Wire #14 at Fuel Shut-Off Solenoid

51

Removing The GeneratorWith the alternator bulkhead removed as shown in figure61, you are ready to begin removal of the Meccalte-Generator.

Blind End Cover Removal

• Remove the four screws holding the cover on the blindend of the generator housing (Figure 62).

Generator Isolation Mounts

• Remove the nuts from the top of the isolation mounts(Figure 63).

NOTE: Do attempt to loosen or remove thehardware that attaches the isolation mounts to theenclosure base.

Removing Stator Mounting Hardware

• Remove the cooling fan grids (Figure 64).

Figure 61 — Meccalte Generator Fully Exposed

Figure 62 — Removing the “Blind End” Cover Screws

Figure 63 — Generator Isolation Mounts

Figure 64 — Removing Cooling Fan Grid



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• Remove the nuts from the bolts that mount the statorhousing to the engine adapter (Figure 65).

Removing Rotor Through-Bolt (“Stay Shaft Bolt”)

WARNING: Do not attempt to stop the rotorfrom turning by placing something under the fins. Therotor cooling fins will break. Warranty will not covera rotor due to this type of fin damage.

• Remove the spark plugs from the engine.

• Insert a length of nylon rope into the cylinder as shownin figure 66A.

• Use a 13mm socket and turn the rotorcounterclockwise until the rope is compressed insidethe cylinder.

• Using a suitable breaker bar, loosen and remove therotor bolt (Figure 66B).

• Support the drive end of the generator with a suitablewooden block.

• Remove the grounding lug from the stator housing(Figure 67).

Using a three-legged gear puller:

• Install the spindle of the puller in the countersunk holeof the rotor shaft (Figure 68).

Figure 67 — Properly Installing the Gear Puller

Figure 65 — Removing Stator Mounting Hardware

Figure 66 — Removing Rotor Through-Bolt

BA

53

• Extend the puller spindle until the housing clears themounting studs and the rotor bearing comes free of thestator housing.

When the stator housing is free of the rotor bearing andmounting studs:

• Disconnect the wiring harness from the terminalblock of the generator (Figure 69).

• Carefully lift and draw the stator housing clear of therotor assembly (Figure 70).

Removing The Rotor Assembly

The rotor assembly is held to the tapered shaft of theengine by means of the rotor through-bolt (“Stay ShaftBolt”). In order to help support the weight of the rotor:

• Install the rotor through-bolt a few turns into thethreads of the engine crankshaft.

NOTE: Do not tighten the rotor through-bolt.Allow at least two threads of space between the nutand the end of the rotor shaft.

With the rotor bolt installed and using a soft rubber mallet:

• Support the rotor with one hand

• Gently tap the rotor on the flat surface of thelaminations until the rotor comes free of the shaft(Figure 71).

Figure 69 — Removing the Hasrness

Figure 70 — Removing the Stator Housing

Figure 71 — Removing the Rotor Assembly


Figure 68 — Installing the Gear Puller


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Inspecting The Rotor Assembly

It is not possible to check the serviceable condition of arotor assembly without de-soldering specific components.

The reading that is obtained by the process shown in figure72 only gives the resistance value of the rotor winding.

It does not show if the diode or the thermal protectiondevice is serviceable. The only way to determine if thesecomponents are serviceable, is to de-solder them from theelectrical circuit of the rotor assembly and check themindividually.

For this reason, rotor replacement should only beconsidered when all other possible faults have beeneliminated.

Figure 72 — Checking Rotor Winding Resistance

55

Model 1815 (12kW) Appendix


App

endi

x

APPENDIX

56



Appendix

Figure 73 — Generator Schematic

57



App

endi

x

FS1

0

14

13

F1

BCR

66

0

0

0FS

HM

15

SW2

AUTO

SW1

MANUALOFF

56

1417

239

66

170

15

0

224

225

T2

T1

95

OTS

T2

224

T1

2250

N2

T1

N1

93 92BW

92

93EW

120V120V

240VAC

T1

T2

T2

CB1

11

44

PO

WE

R W

IND

ING

22

33

NEUTRALL2

J3 J4 J5 J6 J7

SW1

50HZ60

JTAG

RS232 J2

LED LAMP

LOW OIL PRESSURE

STARTER CONTACTOR 12VDC (2A)

IGNITION SHUTDOWN (WHEN CONNECT TO GND)

FUEL SOLENOID VALVE & HOUR METER 12VDC (1A+)MANUAL MODE (+12VDC WHEN ACTIVE)

AUTO MODE (+12VDC WHEN ACTIVE)

CRANK DISCONNECT

SET EXERCISE (GND WHEN ACTIVE)

POWER (+12VDC) AT ALL TIMES BATTERY

GND

TRANSFORMER (20 VAC)

TRANSFORMER (20 VAC)

LOAD VOLTAGE (240 VAC)

LOAD VOLTAGE (240 VAC)

OIL TEMPERATURE

TOTRANSFERSWITCHUTILITYSENSING240VACINPUT

BATTERY CHARGEWINDING

RESISTOR0.5 OHM, 25W

1

2

3

4

5

6

7

9

10

11

12

13

14

15

16

17

18

SC

LOP

85

241

241

J1

L1

0

0

0

0

0

BLACK

BATTERY

12VDC

SMSC

RED

RED

FRAMEGROUND

+12V

DC

GN

D

NO

1C

OM

MO

N 1

NC

1N

O2

CO

MM

ON

2N

C 2

+LE

D L

AM

PG

ND

66

0

0

0

14

77

Figure 74 — CMA Schematic

58



Appendix

GndNeut

A

B

C

D

E

F

Figure 75 — Model 1917 50 Amp Transfer Switch NEMA 1 Typical Wiring Diagram

Main Distribution Panel Model 1917 Transfer Switch

59



App

endi

x

12kW Generator Connections

Gnd

Neutral

A

D

C

B

F

E

Util

itySe

nsin

g

Util

itySe

nsin

g

Figure 76 — Recommended Torque Values (Model 1917)

Connections:In Main Distribution Panel:Refer To Panel Manufacturers’ Specs.

In Transfer Switch:Utility Connection LugsGenerator Connection LugsLine Connection LugsNeutral LugsGround LugsBarrier Terminal Strip Screws

In Generator Housing:Dual Pole Breaker ScrewsGround Lug ScrewsBarrier Terminal Strip Screws

Torque Values

35 in-lb

MaximumMinimum

35 in-lb35 in-lb35 in-lb


5 in-lb

45 in-lb

45 in-lb45 in-lb

45 in-lb27 in-lb


8 in-lb

45 in-lb

Generator

60



Appendix

Red

J4J5J6

J1J2J3

Green

NC1

(Utility)

NC1

NC2

NC2

(Generator)

GndNeut

A

D

C

B

F

E

Figure 77 — Model 1814 200 Amp Automatic Transfer Switch Typical Wiring Diagram


61

App

endi

x



Gnd

Neutral

A

D

C

B

F

E

Util

itySe

nsin

g

Util

itySe

nsin

g

12kW Generator Connections Figure 78 — Recommended Torque Values (Model 1814)


In Transfer Switch:Ground LugsBarrier Terminal Strip Screws


Torque Values

MaximumMinimum


5 in-lb

45 in-lb27 in-lb

50 in-lb8 in-lb

13 in-lb

45 in-lb

Generator

62



Appendix

GndNeut

A

D

C

B

F

E

Figure 79 — Model 1929 200 Amp Transfer Switch with Main Line Disconnect Typical Wiring Diagram


63



App

endi

x

Gnd

Neutral

A

D

C

B

F

E

Util

itySe

nsin

g

Util

itySe

nsin

g

12kW Generator Connections Figure 80 — Recommended Torque Values (Model 1929)


In Transfer Switch:Generator Connection LugsGround Lugs


Torque Values

MaximumMinimum

35 in-lb


45 in-lb

45 in-lb27 in-lb

50 in-lb

13 in-lb

45 in-lb

Generator

64

OIL HEATER



Appendix

Oil Heater1. Remove the control panel and oil service doors as

described on page 7.

2. Set the AUTO/OFF/MANUAL switch to the OFFposition.

3. Set the generator's main circuit breaker to the OFFposition.

4. Disconnect power by removing 2 Amp fuses from insidethe transfer switch.

5. Drain oil from generator as described on page 38.

6. Remove the crankcase plug from the generator throughthe "oil service" access panel of the unit (Figure 81).

7. Place Teflon tape on the threads of the oil heater fitting(figure 82).

8. Install oil heater into engine crankcase. Tighten to ¼ turnpast "snug" (Figure 83).

9. Connect oil heater's 2-pin connector to the 2-pinconnector provided in the units wiring harness (Figure 84).

Figure 81 — Remove plug from engine block.

Figure 82 — Teflon Tape on Heater Threads

Figure 83 — Install Oil Heater

65

10. Service the engine with synthetic oil following the"Changing Oil and Filter" instruction given on page 38.

11. Reconnect power by installing the 2 Amp fuses in thetransfer switch.

12. Set the generator's main circuit breaker to the ONposition.

13. Set the "AUTO/OFF/MANUAL" switch to the "AUTO"position.

14. Clean the area and run the generator at "No Load" untilthe oil is at operating temperature.

15. Check for leaks.

16. Reinstall the access doors.



App

endi

x

Figure 84 — Connect Oil Heater to Wiring Harness

CAUTION: Any attemp to crank or start theengine before it has been properly filled with therecommended oil will result in equipment failure.

• Refer to the proper “Engine Maintenance” sectionof this manual for servicing information.

• Damage to equipment resulting from failure tofollow this instruction will void the enginewarranty.

240 Volt Battery Warmer1. Remove control panel and oil service doors as

described on page 7.

2. Set AUTO/OFF/MANUAL switch on generator'scontrol panel to OFF.

3. Set main circuit breaker to OFF position.

4. Disconnect power by removing 2 Amp fuses insidetransfer switch.

5. Disconnect negative (-) battery cable (Figure 85).

6. Remove battery bracket (Figure 86) and place batteryto the side.

7. Place battery on top of battery tray (Figure 87).

8. Remove the tie wrap securing wiring harness 2-pinconnector.

9. Plug battery warmer's 2-pin connector into wiringharness 2-pin connector (Figure 88).

10. Place battery on top of battery warmer (Figure 89).

NOTE: Do not place battery on top of batterywarmer's leads or thermostat.

66

BATTERY WARMER



Appendix

Figure 85 — Disconnect (-) Negative Battery Cable

Figure 86 — Remove Battery Bracket

Figure 87 — Place Heater on Battery Tray

Figure 88 — Connect 2-Pin Connector

67



App

endi

x

11. Secure battery bracket.

12. Reconnect negative battery cable.

13. Reinstall 2 Amp fuses in transfer switch.

14. Set generator's main circuit breaker to the ONposition.

15. Set AUTO/OFF/MANUAL switch to the AUTOposition.

16. Reassemble the generator enclosure.

Figure 89 — Place Battery on Heater Pad

68



Appendix

Util

ity S

uppl

y24

0VA

C

N1

N2

To

Gen

.U

tility

Sens

ing

F1 F2

600V

AC

2 A

MP

Fuse

N2

N1

N1

556

127

N

NO

NC

NC

NO

128

205

206

E

E1

E1

E2

T2

MA

IN D

IST

RIB

UT

ION

PAN

ELT1

GEN

ERA

TO

R S

UPP

LY24

0VA

CE1 E2

TR

AN

SFER

SW

ITC

H

J3J2

J1J4

J6J5

CO

NT

RO

L BO

AR

D

N.C

. CO

NT

AC

TS

SUPE

RV

ISO

RY

CO

NT

RO

L

Figure 90 — Transfer Switch Schematic (Models 1813 & 1814 100/200 Amp only)