Briggs & Stratton 076000NG User manual

Home Generator System
Manual 278382GS Rev A 6/08
BRIGGS & STRATTON
SERVICE & TROUBLESHOOTING MANUAL
HOME GENERATOR SYSTEM - 30kW

FORWARD
This manual was written to assist authorized technicians and service personnel with the repair and
maintenance procedures for Briggs & Stratton home standby generator systems. It assumes that persons
using this manual have been properly trained in and are familiar with the servicing procedures for these
products, including the proper use of required tools and safety equipment and the application of
appropriate safety practices. Persons untrained or unfamiliar with these procedures or products should not
attempt to perform such work.
Proper maintenance and repair is important to safe, reliable operation of the standby system. The
troubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate for
the models described herein. Alternative methods or procedures may pose risk to personal safety and the
safety and/or reliability of the equipment and are not endorsed or recommended by Briggs & Stratton.
All information, illustrations, and specifications contained in this manual were based on the data available
at the time of publication. Briggs & Stratton Corporation reserves the right to change, alter, or otherwise
improve the product or the product manuals at any time without prior notice.
Copyright © 2008 Briggs & Stratton Corporation
All rights reserved.
No part of this material may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying or recording by any information storage and retrieval system, without
prior written permission from Briggs & Stratton Corporation.

Page i
TABLE OF CONTENTS
SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS......................................1
SAFETY MESSAGES.................................................................................................................. 1
ACCESS TO THE GENERATOR................................................................................................. 5
GENERATOR COMPONENTS.................................................................................................... 6
GENERATOR CLEARANCES..................................................................................................... 9
SYSTEM CONNECTIONS........................................................................................................... 10
FUEL SUPPLY.............................................................................................................................12
ENGINE MAINTENANCE ............................................................................................................ 13
SETTING THE EXERCISE TIMER.............................................................................................. 13
SECTION 2 - TROUBLESHOOTING.................................................................................17
SYSTEM CONTROL PANEL (SCP) ............................................................................................ 17
FAULT CODE INDICATIONS ...................................................................................................... 18
STOPPING THE SYSTEM FOR MAINTENANCE....................................................................... 19
GENERATOR AC CONNECTION SYSTEM................................................................................ 20
(FAULT CODE_1) DEAD UNIT/LOW BATTERY VOLTAGE....................................................... 21
(FAULT CODE_2) LOW OIL PRESSURE ................................................................................... 29
(FAULT CODE_3) LOW OUTPUT VOLTAGE............................................................................. 33
(FAULT CODE_4) ENGINE FAILS TO START/FAILS TO CRANK............................................. 39
(FAULT CODE_5) UNDER FREQUENCY................................................................................... 51
(FAULT CODE_6) OVER FREQUENCY ..................................................................................... 54
(FAULT CODE_7) HIGH TEMPERATURE.................................................................................. 55
(FAULT CODE_8) TRANSFER SWITCH FAILURE ....................................................................58

Page ii
SECTION 3- SPECIFICATIONS & REFERENCE..............................................................59
SPECIFICATIONS........................................................................................................................59
SCHEMATIC ................................................................................................................................60
WIRING DIAGRAM ......................................................................................................................61

1
1
SECTION 1 -SAFETY, MAINTENANCE
AND ADJUSTMENTS
In The Interest Of Safety
This repair manual contains safety information
that is designed to:
• Make you aware of hazards associated
with engines.
• Inform you of the risk of injury associated
with those hazards.
• Tell you how to avoid or reduce the risk
of injury.
The Safety Alert Symbol
The safety alert symbol ( ) is used to identify
safety information about hazards that can result
in personal injury.
A signal word (DANGER,WARNING, or CAUTION)
is used with the alert symbol to indicate the
likelihood and the potential severity of injury. In
addition, a hazard symbol may be used to
represent the type of hazard.
DANGER indicates a hazard which, if
not avoided, will result in death or
serious injury.
WARNING indicates a hazard which, if
not avoided, could result in death or
serious injury.
CAUTION indicates a hazard which, if
not avoided, might result in minor or
moderate injury.
CAUTION:When this signal word is used
without the alert symbol, it indicates a situation
that could result in damage to the engine.
• Prior to work, read and understand the
section(s) of this manual that pertain to
the job. Follow all safety warnings.
• Wear suitable eye protection.
• When servicing engines or equipment,
prevent accidental starting by
disconnecting control panel fuse, spark
plug wire from the spark plug(s), and
disconnect negative battery cable.
• Disconnect all sources of supply voltage
before servicing the generator.
WARNING
Before attempting to service this equipment,
read and understand this manual and the
operating instructions of the equipment
Failure to follow instructions could result in
DEATH, SERIOUS INJURY (including
paralysis) or property damage.
Explosion Fire Electrical
Shock
Toxic
Fumes Rotating
Parts
Hot Surface
Auto Start Explosive
Pressure Chemical
Burn
Lift Hazard Read
Manual
HAZARD SYMBOLS AND MEANINGS

2
1
WARNING
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
WARNING
Storage batteries give off explosive
hydrogen gas during recharging.
Slightest spark will ignite hydrogen
and cause explosion.
Battery electrolyte fluid contains acid
and is extremely caustic.
Contact with battery contents will
cause severe chemical burns.
A battery presents a risk of electrical
shock and high short circuit current.
•DO NOT dispose of a battery in a fire.
•DO NOT allow any open flame, spark,
heat, or lit cigarette during and for several
minutes after charging a battery.
•DO NOT open or mutilate the battery.
•Wear protective goggles, rubber apron,
and rubber gloves.
•Remove watches, rings, or other metal
objects.
•Use tools with insulated handles.
WARNING
Running engine gives off carbon mon-
oxide, and odorless, colorless,
poison gas.
Breathing carbon monoxide can
cause headache, fatigue, dizziness,
vomiting, confusion, seizures,
nausea, fainting, or death.
•Operate generator ONLY outdoors.
•Install a battery operated carbon monox-
ide alarm near the bedrooms.
•Keep exhaust gas from entering a con-
fined area through windows, doors, venti-
lation intakes, or other openings.
WARNING
Generator produces hazardous volt-
age.
Failure to properly ground generator
can result in electrocution.
Failure to isolate generator from
power utility can result in death or
injury to electric utility workers due to
backfeed of electrical energy.
•When using generator for backup power,
notify utility company.
•DO NOT touch bare wires or receptacles.
•DO NOT handle generator or electrical
cords while standing in water, while bare-
foot, or while hands or feet are wet.
•If you must work around a unit while it is
operating, stand on an insulated dry sur-
face to reduce shock hazard.
•DO NOT allow unqualified persons or chil-
dren to operate or service generator.
•In case of an accident caused by electri-
cal shock, immediately shut down the
source of electrical power and contact the
local authorities. Avoid direct contact
with the victim.
•Despite the safe design of the home gen-
erator, operating this equipment impru-
dently, neglecting its maintenance, or
being careless can cause possible injury
or death.
•Remain alert at all times while working on
this equipment. Never work on the equip-
ment when you are physically or mentally
fatigued.
•Before performing any maintenance on
the generator, disconnect the battery
cable indicated by a NEGATIVE,NEG, or
(-) first. When finished, reconnect that
cable last.
•After your home generator is installed, the
generator may crank and start without
warning any time there is a power failure.
To prevent possible injury, always set the
generator’s system switch to OFF AND
remove the 15 Amp fuse BEFORE work-
ing on the equipment.

3
1
WARNING
Propane and Natural Gas are
extremely flammable and explosive.
Fire or explosion can cause severe
burns or death.
•Install the fuel supply system according to
N.F.P.A 37 and other applicable fuel-gas
codes.
•Before placing the home generator into
service, the fuel system lines must be
properly purged and leak tested.
•After the generator is installed, you should
inspect the fuel system periodically.
•NO leakage is permitted.
•DO NOT operate engine if the smell of
fuel is present or other explosive condi-
tions exist.
•DO NOT smoke around the generator,
Wipe up any oil spills immediately. Ensure
that no combustible materials are left in
the generator compartment. Keep the
area near the generator clean and free of
debris.
WARNING
Contact with muffler area can result in
serious burns.
Exhaust heat/gases can ignite com-
bustibles or structures, causing a fire.
•DO NOT touch hot parts and AVOID hot
exhaust gases.
•Allow equipment to cool before touching.
•DO NOT install the generator closer than
5 feet (1.5m) from any combustibles or
structures with combustible walls having a
fire resistance rating of less than 1 hour.
WARNING
Starter and other rotating parts can
entangle hands, hair, clothing, or
accessories.
•NEVER operate generator without protec-
tive housing or covers.
•DO NOT wear loose clothing, jewelry, or
anything that may be caught up in the
starter or other rotating parts.
•Tie up long hair and remove jewelry.
CAUTION
Installing the control panel’s 15A fuse
could cause the engine to start.
•DO NOT install this fuse until all plumbing
and wiring has been completed and
inspected.
CAUTION
Excessively high operating speeds increase
risk of injury and damage to the generator.
Excessive load will cause engine shutdown.
•DO NOT tamper with governed speed.
Generator supplies correct rated fre-
quency and voltage when running at gov-
erned speed.
•DO NOT modify the generator in any way.
CAUTION
Avoid prolonged or repeated skin contact with
used motor oil.
•Used motor oil has been shown to cause
skin cancer in certain laboratory animals.
•Thoroughly wash exposed areas with
soap and water.

4
1
Standby Safety Practices
• This manual contains important safety
messages. Read these carefully and
understand them before proceeding with
maintenance and repairs.
• Become familiar with the Home
Generator System. Know its
applications, its limitations, and any
hazards involved.
• This unit must not be modified for any
application other than that for which it
was designed. If you have any questions
about the home generator System, ask
the dealer or consult Briggs and Stratton.
• Never handle any kind of electrical cord
or device while standing in the water,
while barefoot, or while hands and feet
are wet.
• Worn, bare, frayed, or otherwise
damaged electrical cord sets should not
be used with the Home Generator
System. Using a defective cord may
result is an electrical shock or damage to
the test equipment and/or the unit.
• The Home GeneratorSystem requires an
adequate supply of cooling air for
continued proper operation. Never allow
the free flow of cooling air into or out of
the unit to be obstructed in any way.
• Home Generator Systems produce
powerful voltages that can cause
extremely dangerous electrical shock.
Avoid contact with bare wires, terminals,
etc. Never permit an untrained person to
service or assist with the procedures
discussed in this manual.
• Never manually start or stop this unit with
electrical loads connected to the
receptacles and turned ON. Start the
engine and allow it to stabilize before
connecting any electrical loads. Turn
OFF and disconnect all electrical loads
before shutting down the generator.
• The manufacturer cannot anticipate
every circumstance that might involve or
constitute a hazard. Warnings in
manuals, warnings on hang tags, and
labels affixed to the unit are NOT all-
inclusive. Do not handle, operate, or
service the unit using a procedure or
method that is not specifically
recommended by the manufacturer.
CAUTION
Exceeding generators wattage/amperage
capacity can damage generator and/or electri-
cal devices connected to it.
•See Essential Circuits in the Operator’s
manual.
•Start generator and let engine stabilize
before connecting electrical loads.
CAUTION
Improper treatment of generator can damage
it and shorten its life, or result in personal
injury.
•Use generator only for intended uses.
•If you have questions about intended use,
ask dealer or contact Briggs and Stratton.
•Operate generator only on level surface.
•Adequate, unobstructed flow of cooling
and ventilating air is critical to correct gen-
erator operation.
•The Coolant Fill, Battery, and Control
Panel doors must be installed whenever
the unit is running.
•DO NOT expose generator to excessive
moisture, dust, dirt, or corrosive vapors.
•Despite the safe design of the home gen-
erator, operating this equipment impru-
dently, neglecting its maintenance or
being careless can cause possible injury
or death.
•DO NOT start engine with air cleaner
removed.
•DO NOT insert any objects through the
cooling slots.
•DO NOT use the generator or any of its
parts as a step. Stepping on the unit can
cause stress and break parts. This may
result in dangerous operating conditions
from leaking exhaust gases, fuel leakage,
oil leakage, etc.
•If connected devices overheat, turn them
off and disconnect them from generator.
•Shut off generator if:
-electrical output is lost;
-equipment sparks, smokes, or emits
flames;
-unit vibrates excessively.

5
1
ACCESS TO THE GENERATOR
The home generator is equipped with an
enclosure that has four access doors (Figure 1).
The doors are named for a significant component
located behind them, as follows:
• Control Panel Door
• Coolant Fill Door
• Battery Door
• Exhaust Door
Each Home Standby Generator System is
equipped with two identical keys. These keys fit
all the doors.
NOTE: The Coolant Fill, Battery and Control
Panel doors must be installed whenever the unit
is running, or the generator may overheat.
Figure1
Removing An Access Door
1. Insert key into lock of access door handle you
wish to open and turn one quarter turn
counterclockwise. Remove key. Handle will
remain unlocked until you relock it.
2. Grasp door’s handle and turn one quarter turn
counterclockwise to open.
3. Coolant Fill door is unlocked in the same
manner. It can be used for adding coolant or
engine oil.
NOTE: The enclosure also includes muffler and
radiator access panels, used for cleaning those
components. Those panels should remain closed
at all other times.
Installing An Access Door
1. Mount the door using the notches on the
generator base.
2. Close door and turn handle one quarter turn
clockwise.
3. Insert key into lock in handle and turn one
quarter turn clockwise. Remove key.
WARNING
Contact with muffler area can result in
serious burns.
•DO NOT touch hot parts and AVOID hot
exhaust gases.
•Allow equipment to cool before touching.

6
1
GENERATOR COMPONENTS
NOTE:Generator is shown with access door removed.
A - Oil Dip Stick - Used to check the engine oil
level.
B - Engine Label - Identifies engine model and
type.
C - Oil Fill Cap - Remove to service the engine
with recommended oil.
D - Thermostat - Allows the engine to heat up
quickly, and then to keep the engine at a con-
stant temperature. It does this by regulating the
amount of coolant that goes through the radiator.
E - Coolant Recovery Bottle - Provides visual
indicator of engine coolant level.
F - Oil Filter - Filters engine oil to prolong sys-
tem life.
G - Oil Drain Plug - Provided to facilitate oil
changing.
H - Ignition Coil - Amplifies the voltage of elec-
tricity supplied to the ignition system.
J - Battery Negative Cable - Cable connects
negative battery terminal to various electrical cir-
cuit and to the engine for starting.
K - Oil Pressure Switch - Monitors engine oil
pressure when the engine is running. Indicates a
drop to below the minimum permissible pres-
sure.
L - Starter Contactor/Motor - The starter con-
tactor supplies the high current
needed to run the starter motor and also pro-
vided the force needed to engage the starter.
The starter is an electric motor used to turn over
the engine to start it.
M - Battery Fuse Holder - Provides over-current
protection for safe operation of generator battery.
Fully insulated and water proof.
N - Fuel Solenoid - One inlet and one outlet,
electrically controlled to permit and shut off fluid
flow.
P - Generator Ground - Located on the frame
below the generator circuit breaker cover. If
required by local codes, should ONLY be used
for a ground rod. See System Control Panel for
other Ground locations.
R - Unit Data Decal - Identifies unit by model
and serial number.
S - Stub In Location - Located in bottom of cir-
cuit breaker enclosure for power cable stub in
location. Panel is removable to allow easy hole
cutting for conduit.
T - Circuit Breaker Enclosure - Equipped with
removable bottom to assist with conduit connec-
tion.
U - Automatic Voltage Regulator - Access hole
for voltage regulator adjustment.
V - Control Panel - Used for various tests, oper-
ation, and maintenance functions. See System
Control Panel on the next page.