Briggs & Stratton 40213 Programming manual

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15000 WATT HOME GENERATOR SYSTEM
SERVICE & TROUBLESHOOTING MANUAL
MODELS 040213 & 040234
Part# 276351GS - June 2006

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This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and
company service personnel when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar
products, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in the
recommended servicing procedures for these products, which includes the use of mechanics hand tools and any
special tools that might be required.
Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems.
The troubleshooting, testing, service and repair procedures described in this guide are effective methods of
performing such operations.
We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a
service might be performed, nor of any possible hazards and/or results of each procedure or method. We have not
undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by the
manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be endangered by the
service or operating procedure selected.
All information, illustrations, and specifications contained in this guide are based on the latest production information
available at the time of publication. However, Briggs & Stratton Corporation reserves the right to change, alter, or
otherwise improve the product at any time without prior notice.
Some components or assemblies of the product described in this guide may not be considered repairable.
Disassembly, repair and reassembly of such components may not be included in this guide.
Copyright © 2006 Briggs & Stratton Corporation
All rights reserved.

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Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)
Table Of Contents
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15000 WATT HOME GENERATOR SYSTEM
SECTION 1 - GENERAL INFORMATION ... ............................................................................11
ACCESS TO THE GENERATOR .......................................................................................................11
To remove an access door: ........................................................................................................................... 11
To install an access door: .............................................................................................................................. 11
GENERATOR COMPONENTS ..........................................................................................................12
SYSTEM CONTROLS ........................................................................................................................13
GENERATOR CLEARANCES ...........................................................................................................14
ENGINE MAINTENANCE ...................................................................................................................14
Checking Oil Level ......................................................................................................................................... 14
Changing the Oil and Oil Filter ....................................................................................................................... 14
Replacing the Spark Plugs ............................................................................................................................ 15
Service Air Cleaner ........................................................................................................................................ 15
Valve Lash ..................................................................................................................................................... 15
Cooling Fins ................................................................................................................................................... 15
FUEL SUPPLY ...................................................................................................................................15
Reconfigure The Fuel System ....................................................................................................................... 16
GENERATOR AC CONNECTION SYSTEM ......................................................................................16
SYSTEM CONNECTIONS .................................................................................................................17
Wiring For The 2-Pin Connector: ................................................................................................................... 17
Wiring For The 10-Pin Connector: ................................................................................................................. 17
SETTING THE EXERCISE TIMER ....................................................................................................18
CONTROL MODULE ASSEMBLY (CMA) ..........................................................................................18
Power During CMA Fault Conditions ............................................................................................................. 18
Access To The CMA Board ........................................................................................................................... 19
CMA Connections .......................................................................................................................................... 19
FAULT CODE INDICATIONS .............................................................................................................20
Fault Code Index: .......................................................................................................................................... 20
Resetting The Fault Code Detection System ................................................................................................. 20
STOPPING THE SYSTEM FOR MAINTENANCE .............................................................................20

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)
Table Of Contents
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1SECTION 2 - TROUBLESHOOTING INFORMATION ............................................................23
(FC_1)
DEAD UNIT/LOW BATTERY VOLTAGE: ..........................................................................................23
Test 1
Check Battery: ................................................................................................................................................23
Test 2
Check DC Amperage at Battery: ....................................................................................................................23
Test 3
Check AC Voltage Input: ................................................................................................................................24
Test 4
Measure DC Output Voltage at the CMA .......................................................................................................24
(FC_2)
LOW OIL PRESSURE: .......................................................................................................................27
Test 1
Measure for Short-To-Ground ........................................................................................................................27
Test 2
Check Engine Oil Pressure ............................................................................................................................28
Test 3
Check Oil Pressure Switch .............................................................................................................................28
(FC_3)
LOW OUTPUT VOLTAGE: .................................................................................................................31
Test 1
Measure Circuit Breaker Load-Side Voltage: .................................................................................................31
Test 2
Measure Voltage at E1 and E2 ......................................................................................................................31
Test 3
Measure Circuit Breaker Line Voltage: ..........................................................................................................32
(FC_4)
ENGINE FAILS TO START: ...............................................................................................................35
Troubleshooting Engine Start Failures: ..........................................................................................................35
Test 1
Check Fuel Delivery System ..........................................................................................................................35
Test 2
Visually Inspect Generator .............................................................................................................................35
Test 3
Check Fuel Supply Pressure ..........................................................................................................................36
Test 4
Check Fuel Solenoid. .....................................................................................................................................36
Test 5
Check Fuel Regulator ....................................................................................................................................38

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)
Table Of Contents
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Test 6
Check Ignition Spark: ..................................................................................................................................... 38
Test 7
Check Battery Components ........................................................................................................................... 38
Test 8
Check Starter Contactor Signal ..................................................................................................................... 39
Test 9
Check CMA Board Output ............................................................................................................................. 40
Test 10
Check Starter ................................................................................................................................................. 40
(FC_5)
UNDER FREQUENCY: ......................................................................................................................43
Test 1
Check No Load & Full Load Frequency: ........................................................................................................ 43
Test 2
Measure Frequency at E1 & E2 ..................................................................................................................... 44
(FC_6)
OVER FREQUENCY: .........................................................................................................................45
(FC_7)
HIGH OIL TEMPERATURE: ...............................................................................................................47
Test 1
Check Over Temperature Switch (OTS): ....................................................................................................... 47
Test 2
Check Wire #95 ............................................................................................................................................. 47
(FC_8)
TRANSFER SWITCH FAILURE: ........................................................................................................48
15kW WINDING TEST INDEX ...........................................................................................................49
CHECKING THE STATOR WINDING THROUGH THE HARNESS ..................................................50
CHECKING THE EXCITATION WINDING IN THE GENERATOR ....................................................50
CHECKING THE STATOR POWER WINDING .................................................................................51
CHECKING THE ROTOR WINDING .................................................................................................51

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)
Table Of Contents
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1SECTION 3 - UNIT DISASSEMBLY ........... ............................................................................53
REMOVING THE ACCESS DOORS ..................................................................................................53
REMOVE THE ROOF ASSEMBLY ....................................................................................................53
REMOVE THE EXHAUST BULKHEAD .............................................................................................53
REMOVE THE CONTROL PANEL BULKHEAD ................................................................................54
Remove Battery .............................................................................................................................................54
Remove Control Panel ...................................................................................................................................54
Disconnect Fuel Solenoid ..............................................................................................................................55
REMOVE THE MUFFLER ASSEMBLY .............................................................................................56
REMOVE COOLING DUCTS .............................................................................................................56
REMOVE THE STATOR ASSEMBLY ................................................................................................56
REMOVING THE ROTOR ASSEMBLY .............................................................................................59
INSPECTING THE ROTOR ASSEMBLY ...........................................................................................59
REMOVING THE ENGINE ADAPTOR ...............................................................................................60

Service & Troubleshooting Guide - Home Generator System - Models 040213 & 040234 (15kW)
Table Of Contents
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SECTION 4 - FINAL ADJUSTMENTS AND SPECIFICATIONS ..............................................61
OERATIONAL TESTS ........................................................................................................................61
Manual Operation Test (No Load) ................................................................................................................. 61
Automatic Operation Test (Load Transfer) .................................................................................................... 62
Generator Load Test (Full Rated Electrical Capacity And Fuel Consumption) .............................................. 62
SPECIFICATIONS ..............................................................................................................................64
WIRING DIAGRAM - MODEL 071013 - LOAD CONTROL CENTER ................................................65
SCHEMATIC - MODELS 040213 & 040234 - GENERATOR .............................................................66
WIRING DIAGRAM - MODELS 040213 & 040234 - GENERATOR ...................................................67
SCHEMATIC - MODELS 1813 & 1814 - TRANSFER SWITCH .........................................................68
WIRING DIAGRAM - MODELS 1813 & 1814 - TRANSFER SWITCH ...............................................69
SCHEMATIC - MODELS 071008 & 071009 - TRANSFER SWITCH .................................................70
WIRING DIAGRAM - MODELS 071008 & 071009 - TRANSFER SWITCH .......................................71
SCHEMATIC - MODELS 071010 & 071011 - TRANSFER SWITCH .................................................72
WIRING DIAGRAM - MODELS 071010 & 071011 - TRANSFER SWITCH .......................................73

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