Home Generator System - 18kW and 20kW

Manual 277528GS 7/07

BRIGGS & STRATTON

SERVICE & TROUBLESHOOTING MANUAL
HOME GENERATOR SYSTEM - 18KW AND 20KW

Safety, Maintenance &

Adjustments
1

Troubleshooting 2

Unit Disassembly 3

Specifications & Reference 4

 Home Generator System - 18kW and 20kW
Manual 277528GS 7/07

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 © 2007 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.
TABLE OF CONTENTS

SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS ...................................... 1

SAFETY MESSAGES .................................................................................................................. 1

ACCESS TO THE GENERATOR................................................................................................. 5

GENERATOR COMPONENTS.................................................................................................... 6

SYSTEM CONTROLS.................................................................................................................. 7

GENERATOR CLEARANCES ..................................................................................................... 8

ENGINE MAINTENANCE ............................................................................................................ 8

SYSTEM CONNECTIONS ........................................................................................................... 10

FUEL SUPPLY ............................................................................................................................. 11

SETTING THE EXERCISE TIMER .............................................................................................. 11

OERATIONAL TESTS.................................................................................................................. 11

SECTION 2 - TROUBLESHOOTING ................................................................................. 15

CONTROL MODULE ASSEMBLY (CMA).................................................................................... 15

AUTOMATIC VOLTAGE REGULATOR (AVR) ............................................................................ 16

FAULT CODE INDICATIONS ...................................................................................................... 17

STOPPING THE SYSTEM FOR MAINTENANCE ....................................................................... 18

GENERATOR AC CONNECTION SYSTEM................................................................................ 18

(FAULT CODE_1) DEAD UNIT/LOW BATTERY VOLTAGE ....................................................... 19

(FAULT CODE_2) LOW OIL PRESSURE ................................................................................... 22

(FAULT CODE_3) LOW OUTPUT VOLTAGE ............................................................................. 25

(FAULT CODE_4) ENGINE FAILS TO START/FAILS TO CRANK ............................................. 29

(FAULT CODE_5) UNDER FREQUENCY................................................................................... 35

(FAULT CODE_6) OVER FREQUENCY ..................................................................................... 37

(FAULT CODE_7) HIGH TEMPERATURE .................................................................................. 38

(FAULT CODE_8) TRANSFER SWITCH FAILURE .................................................................... 40

Page i
SECTION 3 - UNIT DISASSEMBLY .................................................................................. 41

REMOVING THE ACCESS DOORS............................................................................................ 41

REMOVE THE ROOF ASSEMBLY .............................................................................................. 41

REMOVE THE EXHAUST BULKHEAD ....................................................................................... 41

REMOVE THE CONTROL PANEL BULKHEAD .......................................................................... 42

REMOVE THE MUFFLER ASSEMBLY ....................................................................................... 44

REMOVE COOLING DUCTS ....................................................................................................... 44

REMOVE THE STATOR ASSEMBLY.......................................................................................... 44

REMOVING THE ROTOR ASSEMBLY ....................................................................................... 47

REMOVING THE ENGINE ADAPTOR......................................................................................... 48

SECTION 4 - SPECIFICATIONS & REFERENCE............................................................. 49

SPECIFICATIONS........................................................................................................................ 49

SCHEMATIC ................................................................................................................................ 50

WIRING DIAGRAM ...................................................................................................................... 51

Page ii
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.
• 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 removing the spark plug
wire from the spark plug(s).
• Disconnect negative battery terminal if the
application is equipped with an electric starting
system.
• Periodically clean engine. Keep governor parts
1
free of dirt, grass and other debris which can
affect engine speed and cooling.
• Check fuel lines and fittings frequently for cracks
or leaks and replace if necessary.

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 used without the alert symbol indicates a

situation that could result in damage to the engine or
equipment.

Page 1
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FRPEXVWLEOHVRUVWUXFWXUHVFDXVLQJDILUH

Page 2
 1

Page 3
 • 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.

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 the factory.
• Never handle any kind of electrical cord or device
while standing in water, while barefoot, or while
hands or 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 in an electrical shock or damage to the
test equipment and/or the unit.
• The Home Generator System requires an
adequate supply of cooling air for continued
proper operation. Never allow the free flow of
cooling air into or out of the unit to become
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 serve or assist with the procedures discussed
in this manual.
• Never 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 electric loads. Turn OFF and
disconnect all electrical loads before shutting
down the generator.

Page 4
ACCESS TO THE GENERATOR Removing An Access Door
• Insert a key into the lock of the access door you
wish to remove and turn one quarter turn
The 20kW Home Standby Generator System is equipped
counterclockwise.
with an enclosure that has three access doors (Fig. 1).
The doors are named for the significant component(s) • Open the latch with a quarter turn
located behind them. Starting with the side that has the counterclockwise.
fuel connection and proceeding clockwise, the doors are • Open the door enough to clear its jambs and lift
named: the door from its hinges.
• Oil Fill Door
• Control Panel Door
NOTE: When removing more than one door at a time,
it’s a good idea to mark the doors for proper fit when
• Oil Drain Door reinstalling.
Each Home Standby Generator System is equipped with
two identical keys. These keys fit all the doors. Installing An Access Door
• Mount the door hinge barrels on their respective
1
CAUTION pins and close.
Do not operate the standby generator for extended • Turn latch a quarter turn clockwise.
periods without all the doors installed and closed. • Lock the door with the key.
Failure to do so will cause overheating.

Fig. 1

Page 5
 GENERATOR COMPONENTS

(A) 15 Amp Fuse - Protects the DC control circuits. (F) Exhaust Port - High performance muffler lowers engine noise to
comply with most residential codes.
(B) Air Cleaner- Protects engine by filtering dust and debris out of
intake air. (G) Oil Dipstick - Used to check engine oil level.

(C) Battery - 12 Volt DC, AGM Type, 55 Amp-Hour sealed battery (H) Oil Drain Hose- Provided to facilitate changing oil.
provides power to start the engine. Battery receives trickle charge
whenever the generator is not running but with utility power present. (I) Oil Fill Cap- Remove to service engine with recommended oil.

(D) Control Panel - Used for various tests, operation and (J) Oil Filter- Filters engine oil to prolong engine life.
maintenance functions. (See “SYSTEM CONTROLS” on page 7.)

(K) Unit Data Decal - Identifies unit by model number, revision and
(E) Engine Label - Identifies engine model and type. serial numbers.

Page 6
SYSTEM CONTROLS
(A) 15 Amp Fuse - Protects the Home Standby Generator
System DC control circuits. If the fuse has melted open or was
removed, the engine cannot crank or start. Replace the fuse
using only an identical ATO 15A fuse.
(B) Circuit Breaker - Protects the system from over current
conditions and must be in the ON position to supply power to
the automatic transfer switch.
(C) Digital Display - Used as an hour meter and to show
various fault indications. (See “FAULT CODE INDICATIONS”
on page 17.)
(D) MANUAL OVER-RIDE- Used to start the engine
manually. Push and hold to start and shut unit down.
(SYSTEM switch must be in AUTO for MANUAL-OVERIDE to
operate.
(F) SET EXERCISE - Used to set the exercise cycle start
time and day of the week. Exercise cycle only occurs in the
AUTO mode.
(G) SYSTEM SWITCH - This two position switch operates
as follows:
• AUTO position is the normal operating mode. If a
utility power outage is sensed, the generator will start
automatically. When utility power is restored, the
generator will shut down and is ready for the next
utility power outage.
• OFF position turn off a running generator, prevents
generator from starting and resets any fault
indications.
Page 7
 GENERATOR CLEARANCES
1 See Fig. 2 below. The minimum clearances of the
generator (B) to combustible materials (D) is 5 feet (1.5
meters) and to non-combustible materials (A) is 2 feet
(.6 meters). Additional clearance may be required to
allow removal of access doors during maintenance. The
minimum clearance from the exhaust side (C) to surface
(E) is 5 feet (1.5 meters).
• These distances are relative only to combustible
materials, and provide for generator cooling and
maintenance access requirements.
• All sides of the generator cannot be enclosed or
restricted, even if the minimum distances are
maintained. DO NOT connect surfaces (A) and/or
(D) to surface (E).
• A roof cannot be used to enclose this area.
• Exhaust (C) must not be allowed to accumulate.
Fig. 2
• (A) Non-combustible surface with Fire
Resistance Rating of 1 hour or greater
• (B) Home Standby Generator
Page 8
• (C) Engine Exhaust
• (D) Combustible surface with Fire Resistance
Rating less than 1 hour
• (E) Any structure or material
ENGINE MAINTENANCE
For detailed servicing information for the Briggs &
Stratton engine, please refer to the VANGUARD™ V-
Twin OHV Repair Manual (#272144), available from
your Briggs & Stratton source of supply.
Checking the Oil Level
Before placing the standby generator in service, and at
each recommended maintenance interval, check the
engine oil level as follows:
1. Remove oil fill door. Clean area around oil fill and
dipstick locations.
2. Remove dipstick. Wipe with clean cloth.
3. Insert dipstick fully. Remove and check oil level.
If oil level is low, remove oil fill cap and slowly add
recommended oil to bring level to the Full mark on the
dipstick. A reusable oil spout is supplied to make it easier
to pour oil into the engine.
Changing the Oil and Oil Filter
Oil capacity is approximately 2-1/2 quarts (80 ounces or
2.3 liters) when changing both oil and filter. Use only
synthetic detergent oil rated for service SJ or higher.
Change oil after every 50 operating hours. Replace oil
filter every 100 operating hours. If the unit is run under
dirty or dusty conditions or in extremely hot weather,
change the oil more often.
Use the following instructions to change the oil while the Servicing the Air Cleaner
engine is still warm:
The engine air cleaner is one of the most important
1. Make sure the SYSTEM switch is set to OFF. areas to maintain. Use only genuine Briggs & Stratton
2. Remove the 15 Amp fuse. parts. Clean the foam pre-filter (if equipped) every 25
3. Un-clip and wipe the oil drain hose clean with a hours and the filter cartridge every 100 hours of
rag. Place the oil drain hose into a suitable operation. Clean or replace more often in dusty or dirty
container. Push the oil drain fitting in and rotate it conditions.
counterclockwise to its stop, and then pull the
fitting outwards. Oil will begin to flow out of the oil
drain hose.
4. After the oil is drained, grasp the oil drain fitting
and rotate it clockwise until it locks in place.
Reposition the oil drain hose in its storage clip.
5. Place a suitable container beneath the oil filter and
remove the filter.
1
6. Coat the gasket of the new filter with fresh clean To service the air cleaner:
engine oil. Turn the new filter clockwise by hand 1. Remove fastener from top of air cleaner cover.
until the gasket contacts the filter adapter, then
tighten 1/2 to 3/4 turn more. 2. Remove fastener from air filter retainer.
7. Fill engine with oil until level is at the FULL mark 3. If equipped, remove foam pre-cleaner from filter
on the dipstick. cartridge and wash in soapy water. Rinse
thoroughly and allow to air dry.
8. Install and tighten the oil fill cap.
4. Clean filter cartridge by tapping gently on a flat
9. Run the engine for one minute and check for surface. Replace if very dirty or damaged.
leaks. Recheck the oil level.
5. Place dry pre-cleaner on filter cartridge, then re-
install cartridge into air cleaner housing.
6. Install the retainer and fastener, then the cover
Replacing the Sparkplugs and fastener.
Replace the sparkplugs every year. Use only the
recommended sparkplugs and make sure they are Do not use petroleum solvents or pressurized air to
gapped to .030 in. (.76 mm). clean the air filter cartridge. Solvents will cause the
1. Stop the engine (See “STOPPING THE SYSTEM cartridge to deteriorate; pressurized air will perforate the
FOR MAINTENANCE” on page 18.) and pull the media.
wires from the sparkplugs.
2. Clean around the sparkplugs and remove them
from the cylinder head.
Adjusting the Valve Lash
3. Inspect the sparkplugs for wear or damage -
Valve lash must be checked every 100 hours of
replace as necessary. Clean off carbon deposits
operation when the engine is cold. Adjust if necessary
on the electrodes using a wire brush or
according to the VANGUARD™ V-Twin OHV Repair
commercial solvent. Do not blast clean.
Manual (#272144). The lash for both intake and exhaust
4. Set the gap as specified above and install the valves is .004 - .006 in. (.10 - .15 mm).
cleaned or new sparkplugs into the cylinder
heads. Torque to 15 lb- ft.

Cleaning the Cooling Fins

Periodically check to make sure the cylinder fins, oil
cooler, screens, and carburetor ducting are free of
leaves, grass, or other debris.

Page 9
 SYSTEM CONNECTIONS

10 Pin Connector

Fault Contacts
1
Transfer Switch
Communications

Remote LED Output

+12VDC,.5Amp Output

240VAC Utility

2 Pin Connector

Wiring For The 2-Pin Connector
240 Volt Utility - Use to hook up the 240V utility leads
from the transfer switch to the generator.
Wiring For The 10-Pin Connector
Fault Contacts - Use NO, COM and NC to hook up a
siren, light, etc. to alert you in case of a fault. Contacts
reverse state upon a fault condition.
Remote LED Output: - Use this to hook up the remote
LED supplied with the generator. The remote LED will
turn on and off in a series of blinks if certain faults are
detected in the generator.
Transfer Switch Communication - Use TxRx and TxRx
GND to transfer switch to monitor generator functions.
+12 Volt DC, .5Amp Output - Internal power supply.

Page 10
FUEL SUPPLY exercise cycle every following Sunday at 10:00 AM (± 30
minutes).

The table below provides approximate fuel supply

To perform the Set Exercise procedure:
requirements at half load and full load to ensure effective
generator operation (Fig. 3). For actual fuel requirements 1. Make sure the control panel fuse is installed and
for the model you are servicing, refer to the appropriate the SYSTEM switch is set to AUTO.
installation manual. 2. Press and hold down the SET EXERCISE switch for
three seconds on the day and time the Home
Standby Generator System is to exercise. The
Natural Gas LP Vapor LED on the control panel will flash until “SET
1/2 Load Full Load 1/2 Load Full Load EXERCISE” is complete.
18kW 160 CuFt/Hr 293 CuFt/Hr N/A N/A
3. Release the SET EXERCISE switch.
160,000 Btu/Hr 293,000 Btu/Hr N/A N/A
If you want to change the day and time the unit
20kW N/A
N/A
N/A
N/A
70.4 CuFt/Hr 141.5 CuFt/Hr
176,825 Btu/Hr 353,650 Btu/Hr
exercises, simply perform the set exercise procedure on 1
the exact day and time you want it to take place.

Fuel Pressures: NG = 5-7” w.c. NOTE: Set exercise will only work if the unit is in the
LP = 11-14” w.c. AUTO mode and this exact procedure is followed. The
These pressures are at FULL LOAD with all gas exerciser will need to be re-set if the 12 VDC battery is
appliances turned ON and operating. disconnected or if you remove the 15 AMP fuse.

Fig. 3

NOTE: Air density is less at high altitudes, resulting in OPERATIONAL TESTS

less available engine power. Engine power will decrease
3.5% for each 1,000 feet (300 meters) above sea level
and 1% for each 10°F (5.6°C) above 77°F (25°C). If the
generator does not output full rated power, make sure
Testing Manual Operation (No Load)
these factors have been considered when determining This test should be done without any electrical loads
total generator load output. connected, as follows:
1. Remove the oil drain and control panel doors.
2. Remove the four screws that secure the circuit
breaker cover, if installed (Fig. 4).
SETTING THE EXERCISE TIMER

The Home Standby Generator System is equipped with

an exercise timer that will start and run the system once
every seven days. During this exercise period, the unit
runs for approximately 20 minutes and then shuts down.
Electrical load transfer does not occur during the
exercise cycle (unless a utility power outage occurs).

A switch on the control panel is labeled SET EXERCISE

(See “SYSTEM CONTROLS” on page 7.).
The day and time at which this switch is pressed is
retained by a memory chip on the Control Module
Assembly (CMA). Every seven days from that day and
time, the CMA will automatically initiate the system Fig. 4
exercise cycle.
For example, if you press the SET EXERCISE switch on 3. Connect voltage and frequency meters to the load
Sunday morning at 10:00 AM, the unit will run an side of circuit breaker.

Page 11
 4. Set the generator’s main circuit breaker to its ON frequency of 62.0 Hz - 62.5 Hz
(closed) position. .
5. Install the 15 Amp fuse in the control panel.
6. Set the SYSTEM switch to AUTO.
7. Make sure that all fuel shut-off valves are open.
8. Push and hold the MANUAL OVER-RIDE button to
start the engine. Do not crank the engine for more
than 10 seconds at a time, and allow the starter
motor to cool for one minute between attempts.

NOTE: If the unit has been idle for an extended period

or if the fuel system has been serviced, air might get
trapped in the fuel lines. It may take a few minutes to
purge the air from the lines before the unit will start.
1
If the unit fails to start:
• Reset fault code detection system. (See Fig. 5
“Resetting the Fault Code Detection System” on
page 17.)
• Make sure fuel is ON.
CAUTION
Do not proceed until you are certain that no-load AC
• Repeat step 8.
voltage and frequency are correct and within the
• Listen for unusual noises, vibration, or other stated limits.
indications of abnormal operation.
• Check for oil leaks, evidence of overheating, or
other problems that may contribute to a no-start 11. Set the SYSTEM switch to OFF. The unit will shut
condition. down.

Let the engine warm up for about five minutes. When

you are satisfied with the operation of the generator:
9. Check voltage and frequency across Wire #11 and
Wire #44. Voltage should read 239VAC-264VAC
and frequency should read 62.0 Hz - 62.5 HZ.
10. Check the voltage across Wire #11 connection
lug and NEUTRAL and then across Wire #44
connection lug and NEUTRAL. Each reading
should be between 119VAC-131VAC.
If no-load voltage and frequency are correct, push and
hold the MANUAL OVER-RIDE button to shut down the
unit.
If no-load voltage and frequency are NOT correct, keep
the unit running and slowly turn the governor adjustment
screw ([A] Fig. 5) as required to obtain a no-load
Testing Auto Operation (Load Transfer)
1. Ensure that utility power is connected to the
UTILITY CONNECTION lugs of the automatic
transfer switch.
2. Ensure that the main line disconnect for UTILITY
POWER is set to ON.
3. Set the generator SYSTEM switch to the AUTO
position. The unit is now set for automatic
operation.
4. Set the main line disconnect for UTILITY POWER
to OFF.
The engine will crank and start when the utility voltage
drops and the (brown out) sensor has timed out. After
starting, the transfer switch will transfer circuit loads to
the generator. Let the system go through its entire
automatic operation sequence.

Page 12

5. Inspect protected loads and ensure that all
anticipated circuits are functioning.
6. With the generator supplying power, turn ON the
main line disconnect (UTILITY POWER).
If the unit has run for 5 minutes or more, it will transfer
the load back to UTILITY POWER within 10 seconds. If
the unit has run for less than 5 minutes, it will continue to
run for approximately 5 to 6 minutes (to warm up the
engine) and then transfer the load back to UTILITY
POWER.
Approximately one minute after the transfer back, the
engine will shut down.
This completes the testing procedures for automatic
operation. The unit will now start automatically when
UTILITY POWER is lost and will supply STANDBY
POWER to the protected circuits in the home.
Testing Generator Load (Electrical Capacity
And Fuel Consumption)
1. Set the generator main circuit breaker to ON.
2. Set the generator SYSTEM switch to AUTO.
3. Set the main line disconnect (UTILITY POWER) to
OFF.
4. The engine should crank and start automatically.
Let the engine stabilize and warm up for about 5
minutes.
Standby power is now supplied to the GENERATOR
CONNECTION lugs of the automatic transfer switch.
5. Turn ON individual loads within the protected
circuits. Continue until the full rated output of the
generator is reached.
6. Turn on all gaseous fuel appliances in the home
before proceeding.
7. Check generator frequency across the
GENERATOR CONNECTION lugs in the transfer
switch. Frequency should read above 57.0 Hz.
If the frequency is below this value, slowly turn the
governor adjustment screw ([A] Fig. 5) as required to
obtain a full-load frequency above 57.0 Hz.
Once the frequency is correct, allow the unit to run at full
rated load for an additional 5 minutes. Then remove load
and check the no-load frequency again.
8. Set the main line disconnect (UTILITY POWER) to
ON. The unit will transfer the load back to
1
UTILITY POWER within 10 seconds.
Approximately one minute after the transfer back, the
engine will shut down.
9. Set the generator main circuit breaker to OFF.
10. Set the generator SYSTEM switch to OFF.
11. Remove all test equipment and reinstall the
circuit breaker cover.
12. Set the generator main circuit breaker to ON.
13. Set the generator SYSTEM switch to AUTO.
14. Install the access doors.
The generator is now in standby configuration.
CAUTION
If the no-load frequency falls out of stated values after
a full-load adjustment has been made, See “(FC_5)
UNDER FREQUENCY” on page 36. or See “(FC_6)
OVER FREQUENCY” on page 37.
Page 13
1

Page 14
SECTION 2 - TROUBLESHOOTING

CONTROL MODULE ASSEMBLY (CMA) How to Access the CMA

The CMA is mounted behind the face of the control panel
([A] Fig. 6).
The Control Module Assembly (CMA) is a printed circuit
board that is integrated with the control panel of the 1. Open and/or remove the control panel door.
Home Standby System. It contains all the logic circuits,
operator controls, and system displays necessary to
operate, program, and protect the generator. In addition,
it also has an access port for a diagnostic service tool for
troubleshooting external system components and
internal control module failures. The CMA interprets and
monitors electrical inputs from all related circuits
throughout the standby installation.
Before replacing the CMA, all other circuits must be
tested to ensure proper operation. When a failure has
been traced to the CMA, the board must be replaced as
a complete assembly. 115-0005
Functions of the CMA:
• Battery Trickle Charge
• Set Exercise Timer (SET EXERCISE) Fig. 6
• Manual Start (MANUAL OVER-RIDE) 2. Make sure the SYSTEM switch is set to OFF.
• Sensing Utility Voltage 3. Remove the 15 AMP fuse.
2
• Automatic Start, in event of utility failure 4. Disconnect the negative (-) battery cable.
• Automatic Engine Cool-Down Timer 5. Remove the circuit breaker cover ([B] Fig. 6).
• Fault Detection with Automatic Shutdown 6. Disconnect the 2-pin and 10-pin connectors from
the edge of the CMA board.
• Fault Indication Display (LED)
7. Remove the four mounting screws ([C] Fig. 7) that
• Diagnostic Access Port (SERVICE TOOL)
secure the face of the control panel, then carefully
• Hour Meter remove and tilt down the panel to expose the
board.

Power During CMA Fault Conditions

When the Home Generator System experiences a fault
condition, the automatic transfer switch automatically
defaults to UTILITY POWER. This ensures that utility
power is available to all circuits in the home until the fault
is corrected.

If the unit fails to exercise at its prescribed time, check

for a fault code on the generator control panel display. If
no fault code is shown, perform the SET EXERCISE
procedure.

Fig. 7

Page 15
 The CMA is connected to its various circuits through The functions of the 8-pin connector is shown below (Fig.
three connectors that are mounted directly to the board 10).
(Fig. 8), shown tilted down.

Pin 8 Vacant
The 8-pin connector (A) is wired to the internal systems
of the unit and is the primary point of measurement for Pin 7 Vacant
troubleshooting. The 2-pin connector (B) supplies Pin 6 Oil Pressure (Wire #85)
240VAC from UTILITY power. The 10-pin connector (C) Pin 5 Oil Temperature (Wire #95)
is used for optional generator features. In addition, the
CMA also has connections for E1 and E2 (D), which Pin 4 Fuel Solenoid (Wire #14)
sense 240VAC on the generator, and four terminals (E), Pin 3 Start Circuit (Wire #56)
which are used for optional battery and engine warmers Pin 2 Ground (Wire #0)
.
Pin 1 Battery Trickle Charge (Wire #13)

Fig. 10

AUTOMATIC VOLTAGE REGULATOR

(AVR)

The Automatic Voltage Regulator (AVR) is mounted on

2 the bulkhead ([A] Fig. 11) behind the CMA (associated
wiring is removed for clarity).
Fig. 8
20k-50

To show probe locations for troubleshooting with a test

meter, an arrow from a connector/pin illustration will be
shown against the exposed CMA board (Fig. 9). Note
that the board will be shown upside down in relation to
the actual schematic in the manual.

8
7
6
5
4
3
2
1 Fig. 11

Fig. 9

Page 16
The spades at #1 and #4 ([A] Fig. 12) connect to the For example, “FC_1” on the control panel display
brush leads. Spades #2 and #6 (B) connect to the indicates Low Battery Voltage and the remote LED
excitation windings (DPE) of the stator. Spade #0 (C) is would repeatedly flash once with a pause until it’s reset
connected to the system ground. Spade #56 (D) is or the condition is corrected. “FC_2” Low Oil Pressure
connected to the contactor of the starter motor. Spades would cause the remote LED to repeatedly flash twice
#11A and #44A (E) are sensing wires for the 240V output and pause. Following is a list of the possible fault codes.
of the stator power windings.
(FC_1) Low Battery Voltage
(FC_2) Low Oil Pressure
(FC_3) Low Output Voltage
(FC_4) Engine Fails To Start
(FC_5) Low Frequency
(FC_6) Engine Overspeed
(FC_7) High Oil Temperature
(FC_8) Transfer Switch Failure

Resetting the Fault Code Detection System

After correcting the failure indicated by the fault code, the
operator or technician must reset the fault detection
system before the Home Standby System will operate.
1. Place the SYSTEM switch in the OFF position for 5
seconds or more. 2
2. Place the SYSTEM switch in the AUTO position.
Fig. 12
If the fault is not corrected, the unit will return to Auto
Shutdown and the same fault code indication(s) will be
displayed.

FAULT CODE INDICATIONS

The CMA is equipped with sensing circuits that

automatically shut down the generator in the event of
potentially damaging conditions.
A digital display on the face of the control panel will show
the type of failure (Fault Code) that has occurred. An
optional LED indicator can be mounted elsewhere in the
system to provide a remote indication of generator
failures.
When the CMA senses a condition that prevents the
generator from functioning properly, it shuts down the
generator and displays the fault code on the control
panel. At the same time, it signals the remote LED to
flash in a sequence that corresponds to the fault code.

Page 17
 STOPPING THE SYSTEM FOR
MAINTENANCE

1. Ensure the main line disconnect (MLD) is ON and

power is supplied to the UTILITY CONNECTION
lugs of the transfer switch.
2. Set the generator SYSTEM switch to OFF.
3. Set the generator main circuit breaker to OFF.
4. Remove the 15 AMP fuse, as appropriate to your
maintenance needs.

2 GENERATOR AC CONNECTION
SYSTEM

A single-phase, three-wire AC connection is used in the

Home Generator System. The stator assembly consists
of a pair of stationary windings with two leads brought
out of each winding. The two windings are connected
together in series, resulting in a fixed 240VAC, 60Hz
output. Stator output leads #11 and #44 are the two hot
leads. The junction of leads #22 and #33 forms the
neutral lead (Fig. 13).

Fig. 13

Page 18
TROUBLESHOOTING FAULT CODE INDICATIONS

(FC_1)
DEAD UNIT/LOW BATTERY VOLTAGE

Test 2

Yes Measure DC
Test 1 Amperage on
OK?
Check Battery Wire #13 at
battery.
No

Charge/Replace Battery

2
Test 3
Check AC voltage (+) Amp
No Yes END
input at CMA 2-Pin Flow?
connector.

Test 4
Measure DC
12VDC? No Replace CMA
240VAC? Yes Voltage at
CMA on Pin #1,
Wire #13 Yes
No

Check and repair fuses, Repair wiring/

wiring and connections connections between
in the ATS. CMA and battery.

Fig. 14

Page 19
 (FC_1)
DEAD UNIT/LOW BATTERY VOLTAGE
If the generator cannot start because the battery output
power is below that needed to crank the engine, the
digital display will show FC_1 and the remote LED will
repeatedly flash once with a pause. If the system is
equipped with the optional Statstation™ feature, “Low
Battery Voltage” will be displayed on the StatStation
screen.
Note, however, that a completely discharged battery will
not be capable of powering any of these displays.
The causes for a low or discharged battery may be:
• Blown fuse in the transfer switch
• Blown fuse in the generator
• Failed battery
• Parasitic drain on the battery
• Failed trickle charger
The circuit functions and test/repair procedures for these
conditions are outlined below.
2 See “SCHEMATIC” on page 50. for circuit details. Refer
to Fig. 14 at left for troubleshooting flow.
NOTE: The trickle charge circuit is a float charger type.
When UTILITY voltage is present and the unit is
switched to the AUTO or OFF position, the trickle charge
circuit in the CMA will maintain the voltage of a fully
charged battery. The trickle charger may take as long as
three days to fully charge a dead battery.
NOTE: 240VAC UTILITY is delivered from the fuses in
the transfer switch to the 2-pin connector mounted
directly to the CMA board. The CMA uses internal
circuits to rectify this UTILITY voltage to 12VDC. This is
then delivered to the (+) battery post through the 15 Amp
fuse via Pin #1, Wire #13.
Page 20
Test 1 - Check Battery
1. Set SYSTEM switch to OFF.
2. Remove the 15 Amp fuse.
3. Disconnect battery cables, negative (-) first.
4. Using the approved procedure for your battery
tester, check the battery state-of-charge.
If the battery is discharged, connect to an appropriate
battery charger. Set the charger at 2 Amps until full
charge is indicated. Do not exceed the 2 Amp charge
rate.
If battery replacement is required, the replacement must
be the same 12VDC, AGM type, 33 Amp-hour battery.
Do not replace with liquid electrolyte (lead-acid) type
battery.
5. Connect the battery cables, positive (+) first.
6. Reinstall the 15 Amp fuse.
7. Set SYSTEM switch to AUTO, then push and hold
MANUAL OVER-RIDE to start the unit.
Test 2 - Check DC Amperage at Battery
1. Ensure utility power is turn ON to the transfer
switch.
2. Set SYSTEM switch to OFF.
3. Remove the 15 Amp fuse.
4. Disconnect the positive (+) battery cable.
5. Connect DC Amp meter between positive (+)
battery terminal and positive (+) battery post.
6. Install the 15 Amp fuse.
7. Observe the reading on the meter.
• If negative (-) or zero current flow, proceed to
Test 3.
• If positive (+) current flow, the charging system is
working. Continue with Steps 8-11.
8. Remove the 15 Amp fuse.
9. Reconnect the positive (+) battery cable.
10. Reinstall the 15 Amp fuse.
11. Set SYSTEM switch to AUTO, then push and hold
MANUAL OVER-RIDE to start the unit.
Test 3 - Check Utility Voltage Input
1. Set SYSTEM switch to OFF.
2. Remove the 15 Amp fuse.
3. Remove the control panel cover to gain access to
the CMA board. (See “How to Access the CMA”
on page 15.)
4. Check for 240VAC at the pins of the connector
(Fig. 15).
On Site
Fig. 15
• If 240VAC is present, proceed to Test 4.
• If 240VAC is not present, continue with Steps 5-
11.
5. Check for utility voltage in the transfer switch.
6. Check for blown 2 Amp fuses in the transfer
switch
7. Check the wiring and connections between the
transfer switch and the generator.
8. Repair the wiring and/or fuses in the transfer
switch circuit, then recheck for 240VAC at the 2-
pin connector.
9. Reinstall the control panel cover.
10. Reinstall the 15 Amp fuse.
11. Set SYSTEM switch to AUTO, then push and hold
MANUAL OVER-RIDE to start the unit.
Test 4 - Measure DC Output Voltage at the
CMA
1. Ensure that the 15 Amp fuse is installed.
2. Disconnect the negative (-) battery cable.
3. Ensure utility power is turned on. Set the meter to
test DC Voltage.
4. Insert the positive (+) test lead of the meter at Pin
#1, Wire #13 (Fig. 16). Insert the negative (-) test
lead of the meter at Pin #2, Wire #0.
If no voltage is measured, replace the CMA.
If voltage is present, the CMA is good. Next, check that
voltage is reaching the battery:
5. Connect the positive (+) test lead of the meter to
Wire #13 at the battery. Connect the negative (-)
test lead of the meter to the negative (-) battery
cable (not the battery post). The meter should
read 12VDC.
8
2
7
6
5
4
3
2
1
Fig. 16
• If no voltage is present at the battery
connections, repair or replace wire #13 and
retest.
Page 21
 Test 1
(FC_2)
Measure for Low Oil Pressure Test
short-to-ground
on Wire #85.

END

Shorted? Yes Repair/replace

Wire #85
No
No
2
Reset FC Fault Reset FC
Start Unit Detected? Start Unit
Test 2
Measure
engine oil Yes
pressure.

No Replace oil
pressure switch.
Test 3
Within Check Switch
Yes
Spec? oil pressure OK?
switch.
No Yes Replace CMA

Repair/replace
engine as
required.

Fig. 17

Page 22
(FC_2)
LOW OIL PRESSURE
The standby generator is equipped with a Low Oil
Pressure (LOP) switch. The contacts of the switch are
normally closed, but are held open by engine oil
pressure during operation. Should the engine oil
pressure drop below 8 psi, the contacts will close. This
completes a circuit to ground on Wire #85 and the CMA
shuts the engine down.
The digital display will show FC_2 and the remote LED
will repeatedly flash twice with a pause. If the system is
equipped with the optional Statstation™ feature, “Low Oil
Pressure” will be displayed on the StatStation screen.
Test 1 - Measure for Short-To-Ground
1. Set the SYSTEM switch to OFF.
2. Remove the 15 Amp fuse.
3. Remove utility voltage.
4. Remove the control panel cover to gain access to
the CMA board. (See “How to Access the CMA”
on page 15.)
5. Remove the 8-pin connector from the CMA.
6. Remove Wire #85 from the LOP switch.
7. Measure for short-to-ground on Wire #85 (Fig. 18).

During cranking and immediately after engine start, the

following occur:
• The CMA bypasses the LOP switch for several
seconds during initial cranking.
• The LOP switch opens when engine produces
sufficient oil pressure.
• The CMA senses that the engine is running by
monitoring frequency on Wires #E1 and #E2. 2
• After the CMA senses that the engine is running, Fig. 18
it looks for a ground on Wire #85. If no short is detected, proceed to Test 2.
If Wire #85 is grounded, the CMA shuts the engine down If a short is detected, continue with Steps 8-14.
and displays FC_2 at the control panel. 8. Repair and/or replace wiring, as necessary, then
retest.
Refer to Fig. 17 at left for troubleshooting flow.
9. Reconnect Wire #85 to the LOP switch.
10. Reconnect the 8-pin connector to the CMA.
11. Re-install the control panel cover.
12. Re-install the 15 Amp fuse.
Correcting Low Oil Pressure 13. Reset the fault code detection system.
1. Fix any obvious oil leaks and, if necessary, add 14. Set SYSTEM switch to AUTO, then push and hold
the recommended oil to the FULL mark on the MANUAL OVER-RIDE to start the unit.
dipstick.
2. Reset the fault code detection system. (See
“Resetting the Fault Code Detection System” on
page 17.)
3. Start the generator (See “Testing Manual
Operation (No Load)” on page 11.) and listen for
any abnormal sounds that might indicate engine
damage from low oil.
If a low oil pressure condition still exists, the engine will
shut down after approximately 10 seconds and the
control panel will again display FC_2. Proceed to Test 1.

Page 23
 Test 2 - Check Engine Oil Pressure
1. Remove the oil pressure switch and install an oil
pressure gauge.
2. Re-install the 8-pin connector at the CMA board.
3. Re-install the control panel cover.
4. Re-install 15 Amp fuse.
5. Set SYSTEM switch to AUTO, then push and hold
MANUAL OVER-RIDE to start the unit.
6. Pressure reading on gauge should be 10 - 50 PSI
(0.7 - 3.5 Bar).

If oil pressure is normal, proceed to Test 3.

If oil pressure is low, re-install the LOP switch and
connect Wire #85. See VANGUARD™ V-Twin OHV
Repair Manual (#272144) to troubleshoot the source of
low oil pressure.

Test 3 - Check Oil Pressure Switch

1. With the LOP switch installed, start the engine.
(See “Testing Manual Operation (No Load)” on
page 11.)
2 2. Check the switch with a continuity tester. The
switch contacts should be open (no continuity).

If the switch is OK, replace the CMA.

If the switch is defective (continuity), replace it and
continue with Steps 3-8.
3. Reset the fault code detection system. (See
“Resetting the Fault Code Detection System” on
page 17.)
4. Start the generator. (See “Testing Manual
Operation (No Load)” on page 11.)
5. Set SYSTEM switch to OFF.
6. Turn UTILITY ON (if turned off).
7. Return SYSTEM switch to AUTO.
8. Reset the Exercise Timer (See “SETTING THE
EXERCISE TIMER” on page 11.).

Page 24
:
(FC_3) Low Output Voltage
Test 1
Measure circuit
breaker load-side
voltage.

Yes END
Test 2
240VAC? Yes Measure voltage 240VAC? Yes Replace CMA Output
OK?
at CMA

No No No

Test 3 Repair/replace
Measure circuit 240VAC? Yes open wires E1 & E2 Output No
breaker line-side between CB output OK?
voltage. and CMA
Yes
No
2
Cycle CB
Measure CB Output Yes END
Input OK?

No
Test 4
Check field Yes
flash.
Replace Output No
Circuit Breaker OK?

Yes OK? No Repair Wiring

END

Yes

Replace Voltage Regulator Output No

OK?

Test 5
No
By-Pass AVR
OK? Yes

Fig. 19

Page 25
 (FC_3)
LOW OUTPUT VOLTAGE About 240VAC should be measured.

The low voltage shutdown feature is designed to protect

the generator and its loads from an output voltage that is
too low. When the generator has stabilized, the CMA
senses output voltage on Wires #E1 and #E2. (See
“WIRING DIAGRAM” on page 51.) If the CMA does not
sense the proper generator voltage, it will shut down the
unit.
The digital display will show FC_3 and the remote LED
will repeatedly flash three times with a pause. If the
system is equipped with the optional Statstation™
Fig. 20
feature, “Low Output Voltage” will be displayed on the
StatStation screen. If the specified voltage is present, proceed to Test 2.
If specified voltage is not present, proceed to Test 3.
Low output voltage may be caused by:
• A generator that is overloaded
• A restriction in the fuel flow Test 2 - Measure Generator Voltage at CMA
• A broken or disconnected signal lead (E1 or E2). 1. Remove control panel cover to gain access to the
• Diminished engine power CMA board. (See “How to Access the CMA” on
2 • A failed alternator winding page 15.).
• An open control panel circuit breaker 2. With the unit running, measure for 240VAC at
CMA pins E1 and E2 (Fig. 21).
• Open wiring

Test 1 - Measure Circuit Breaker Load-Side

Voltage
1. Remove the cover from the generator circuit
breaker. (See “Testing Manual Operation (No
Load)” on page 11.)
2. Reset the fault code detection system. (See
“Resetting the Fault Code Detection System” on
page 17.)
3. Ensure that the generator circuit breaker is ON
and the 15 Amp fuse is installed.
4. Start the generator. (See “Testing Manual Fig. 21
Operation (No Load)” on page 11.)
If no voltage is present:
5. When the unit has stabilized, check for 240VAC at
1. Ensure the circuit breaker is ON
the load side of the circuit breaker (Fig. 20).
2. Repair or replace the wires between the circuit
breaker and E1 and E2
3. Retest for 240VAC.
If 240VAC is present, replace the CMA board.

Page 26
Test 3 - Measure Circuit Breaker Line-Side
Voltage
1. Ensure the circuit breaker in ON.
2. Start the generator and measure for 240VAC on
the line-side of circuit breaker.
If there is no voltage on the line side of the breaker,
proceed to Test 4.
If there is voltage on the line side of the breaker, but
none on the load-side, manually cycle the circuit breaker
and retest. If there is still no voltage on the load side,
replace the circuit breaker.
Test 4 - Check Field Flash
During the crank cycle, approximately 12VDC is
delivered on wire #56 to excite the generator field and
turn on the AVR. After the crank cycle terminates, this
field flash voltage stops. To test the field flash:
1. Remove the panel screws and the CMA (do not
disconnect any wires) to gain access to the AVR.
2. Push and hold the MANUAL start button.
3. Set the meter to test DC Voltage. While the
generator is cranking, measure the voltage
between wire #56 (positive) and wire #0 (ground)
at the AVR. Approximately 9 to 12VDC should be
present.
If battery voltage is present, proceed to Step 4.
If no battery voltage is present, repair open in wire #56
or wire #0.
4. Check for continuity between wire #0 on the AVR
and the negative (-) battery terminal.
If continuity is present, proceed to Test 5.
If no continuity is present, repair or replace wire #0 to
system ground.
Test 5 - Bypass the AVR
NOTE: Bypassing the AVR will test all wiring and
windings within the alternator without disassembly of the
generator. Verify that the battery voltage is at least 12
volts and the connections are good before proceding
with this test.
1. Set the SYSTEM switch to OFF.
2. Remove the 15 Amp fuse.
3. Switch the generator circuit breaker OFF.
4. Remove wires #1, 4, 11A, 44A, 2, and 6 from the
AVR.
5. Disconnect wire #11 and wire #44 from the line
side of the circuit breaker
There are five AC Voltage checks to be performed, as
follows. The exact voltage readings may vary depending 2
on ambient temperature, battery voltage, meter
calibration, etc. All AC Voltage readings should be within
1-3 volts of each other. A winding that measures outside
this limit, or that has no voltage at all, is considered
shorted.
NOTE: An open in the rotor could cause lowered voltage
readings during these tests. Check and record all the
voltage readings first, then check and record the
amperage draw on the rotor.
• If all readings are within spec, the alternator is
good and the voltage regulator is suspect.
• If one or several voltage readings are low, the
stator is suspect.
• If all voltage readings are low, the rotor is
suspect.
1. Set meter to measure AC Voltage. Connect one
test lead to wire #2 and the other lead to wire #6.
2. Connect a jumper wire from battery positive (+) to
wire #4. Then connect another jumper wire from
battery negative (-) to wire #1.
3. Re-install the 15 Amp fuse.
4. Connect the CMA to generator wiring, but do not
mount the CMA in the panel. Avoid contact with
any bare wires.
Page 27
 5. Manually start the unit and measure AC voltage There is one DC Amperage test to perform. The exact
across wire #2 and wire #6. A minimum of amperage readings may vary depending on ambient
60VAC should be measured. temperature, battery voltage, meter calibration, etc.
If at least 60VAC is measured, proceed to Step 5. If less
than 60VAC is measured, replace stator. 1. Disconnect wire #1 from the battery negative (-).
6. Set SYSTEM switch to OFF. 2. Connect the meter in series between the 12 volt
7. Remove the 15 Amp fuse. battery negative (-) and wire #1.
8. Connect one test lead to wire #22 (NEUTRAL) 3. Manually start the unit and measure DC
and the other lead to wire #11. amperage. Reading should be 0.6-0.75 amps.
9. Re-install the 15 Amp fuse. If reading is within range, the rotor is good.
10. Manually start the unit and measure AC voltage High amperage indicates a short. Verify correctness and
across wire #11 and wire #22. A minimum of condition of wiring, repair as necessary, then retest. If
60VAC should be measured. the reading is still high, replace the rotor.
If at least 60VAC is measured, proceed to Step 11. If Low or no amperage indicates an open. Verify the
less than 60VAC is measured, replace stator. meter’s fuse is good, then retest. If the reading is still
11. Set SYSTEM switch to OFF. low, verify the correctness and condition of the wiring
between the AVR and the alternator. Repair as
12. Remove the 15 Amp fuse.
necessary, then retest. If reading is still low, replace the
13. Connect one test lead to wire #22 (NEUTRAL) rotor.
and the other lead to wire #11A.
4. Disconnect the battery from wire #1 and wire #4
14. Re-install the 15 Amp fuse.
5. Restore wiring connections to the circuit breaker
15. Manually start the unit and measure AC voltage and the AVR.
across wire #11A and wire #22. A minimum of
60VAC should be measured.
2 If at least 60VAC is measured, proceed to Step 15. If
less than 60VAC is measured, replace stator.
16. Set SYSTEM switch to OFF.
17. Remove the 15 Amp fuse.
18. Connect one test lead to wire #22 (NEUTRAL)
and the other lead to wire #44.
19. Re-install the 15 Amp fuse.
20. Manually start the unit and measure AC voltage
across wire #44 and wire #22. A minimum of
60VAC should be measured.
If at least 60VAC is measured, proceed to Step 20. If
less than 60VAC is measured, replace stator.
21. Set SYSTEM switch to OFF.
22. Remove the 15 Amp fuse.
23. Connect one test lead to wire #22 (NEUTRAL)
and the other lead to wire #44A.
24. Re-install the 15 Amp fuse.
25. Manually start the unit and measure AC voltage
across wire #44A and wire #22. A minimum of
60VAC should be measured.
If at least 60VAC is measured, proceed to DC
Amperage check below. If less than 60VAC is
measured, replace stator.

Page 28
 (FC_4) Engine Fails To Start
Test 1 Test 2 Test 3
Check Fuel OK? Yes Visually inspect OK? Yes Check Fuel
Delivery System Generator Supply Pressure
No No
Repair/Correct Repair/Correct
Yes OK? No

Start? No Start? No
Repair/Correct
Yes END Yes

Test 4 No Start?
Check Fuel Test 5
Solenoid OK? Yes Check Fuel OK? Yes Test 6 Yes
Regulator Check Spark
No No

END
Repair/Correct Repair/Correct Yes OK?

No
Yes
Start? No
Start? No Repair Start? No

Yes END Yes 2

(FC_4) Engine Fails To Crank

Test 10
Test 7 Test 8 Check Starter
OK? Yes
Check Battery Check Starter
OK? Yes
Contactor No
Components
No
Signal.

OK? No Repair/Correct
Test 9
Repair/Correct Check CMA
Output.
Yes Start? No

Start? No Replace Yes

OK? No
CMA
Yes Yes

Repair/Correct Wiring Start? Yes END

END No

Fig. 22

Page 29
 (FC_4)
ENGINE FAILS TO START Starting Failures

Test 1 - Check Fuel Delivery System

Whenever the unit is directed to start (MANUAL or
1. Ensure that adequate fuel is available to operate
AUTO), the CMA delivers 12VDC from pin #3, wire #56 to
the standby system.
the starter contactor for 15 seconds. It then pauses for
15 seconds and repeats the attempt until 2 minutes of 2. Verify that the main fuel supply valve and any in-
start time have accumulated. line fuel valves are open.
During the starting attempt, the CMA also delivers
12VDC from pin #4, wire #14 to the fuel solenoid and
NOTE: Fuel shut-off valves are often installed as a
monitors wires #E1 and #E2 for a minimum frequency discretionary convenience to the owner. The number of
signal. This signal indicates that the engine has started shut-off valves may vary with each installation.
and delivery of voltage to the starter contactor is
discontinued. However, if the minimum frequency signal 3. Correct any fuel supply problems.
has not been sensed after approximately 2 minutes of 4. Reset the fault code detection system.
accumulative start time, the CMA terminates the engine 5. Select MANUAL-OVERIDE at the SYSTEM switch.
cranking cycle.
The digital display will show FC_4 and the remote LED If the unit still does not start, go to Test 2.
will repeatedly flash four times with a pause. If the
system is equipped with the optional Statstation™
feature, “Engine Failed To Start” will be displayed on the
StatStation screen. Test 2 - Visually Inspect Generator
2 1. Remove all three access doors to the unit.
This fail code directs the service technician to examine 2. Remove the 15 Amp fuse, then inspect for any
systems that could be preventing the unit from operating. obvious broken or corroded electrical
For example: connections.
• No Fuel 3. Gain access to the CMA board (See “How to
• Fuel Solenoid Failure Access the CMA” on page 15.).
• 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 4. Visually inspect the condition of all wiring,
connectors, and terminals associated with the
following components:
• Oil Pressure and Oil Temperature
Troubleshooting Engine Start Failures
• # 1 Sparkplug Lead
1. Reset the fault code detection system. (See Remove the lead and ensure the plug is tight.
“Resetting the Fault Code Detection System” on
• Starter Contactor
page 17.)
• Fuel Solenoid
2. Set SYSTEM switch to AUTO and push MANUAL-
OVERIDE to start unit. • Generator and Engine Grounds
• Starter Motor
The engine will either crank and fail to start, or it may not • # 2 Sparkplug Lead
crank at all. Use Tests 1-6 for starting failures and Tests Remove the lead and ensure the plug is tight.
7-10 for cranking failures. • All component connections

Page 30
 • 8-Pin connector and each of its wires. Test 4 - Check Fuel Solenoid
• 10-pin connector and each of its wires. 1. Check for 7-12 volts DC at the fuel solenoid while
• 2-pin connector and each of its wires. the engine is cranking (Fig. 24).
5. Repair and/or replace any damaged wiring or
terminal connections.
6. Reset fault code detection system (See “Resetting
the Fault Code Detection System” on page 17.).
7. Attempt MANUAL start and observe system
operation.
If there are no obvious electrical faults, and the problem
persists, go to Test 3.

Test 3 - Check Fuel Supply Pressure

1. Install a temporary manometer, as illustrated in
(Fig. 23) to verify that fuel pressure is available to
the fuel solenoid.
Fig. 24
If no voltage is present at the fuel solenoid, check for
voltage at Pin #4, Wire #14 at the CMA 8-pin connector
(Fig. 25).

LPG = 11 to 14 in. w.c.

NG = 5 to 7 in. w.c.
Fig. 23
If the proper fuel pressure is not present, repair and/or
replace the fuel delivery system, then re-test the fuel
pressure as described above.
If fuel pressure is acceptable, go to Test 4.
Fig. 25
If no voltage is present at the CMA, replace the CMA/
Control Panel.
If voltage is present at the CMA but not at the solenoid,
repair or replace the wiring between the CMA board and
the fuel solenoid (Wire #14).
If voltage is present at both the CMA and the solenoid,
proceed to Step 2.

Page 31
 2. Remove the pipe plug in the regulator test port
and install a manometer (Fig. 26).
Fig. 26
3. Manually start the engine (See “Testing Manual
Operation (No Load)” on page 11.). Fuel pressure
should measure LPG = 11-14 in. w.c.or NG = 5-7
in. w.c.
If the manometer shows a drop in fuel pressure, or no
fuel pressure is measured, replace the fuel solenoid.
If the fuel pressure is measured within specifications, the
2 solenoid is good. Proceed to Test 5.
Test 5 - Check Fuel Regulator
The fuel regulator has two atmospheric vent holes ([A]
Fig. 27) that balance diaphragm pressures.
Fig. 27
1. Install a 1/8 NPT barb fitting into one hole. Attach
a 2 ft. length of hose to the fitting.
2. Plug the other vent hole, then gently blow into the
hose.
Page 32
With the fuel solenoid energized (open), this gentle
pressure will allow fuel to pass through the regulator and
will be indicated on the manometer as a decrease in
pressure.
If no fuel flow is detected, replace the fuel regulator.
If fuel flow is detected, see VANGUARD™ V-Twin OHV
Repair Manual (#272144) to determine the condition of the
gaseous fuel carburetor.
Test 6 - Check Ignition Spark
1. Turn off the manual fuel valve to the standby
generator.
2. With the sparkplug installed, attach #19368 ignition
tester to a sparkplug lead and ground the other
end of the tester as shown in (Fig. 28).
On Site
Fig. 28
3. Set SYSTEM switch to AUTO and push MANUAL-
OVERIDE to crank unit.
If spark jumps the tester gap, the ignition system is
functioning properly.
If there is no spark, see VANGUARD™ V-Twin OHV Repair
Manual (#272144) to troubleshoot the ignition system.
Cranking Failures Test 8 - Check Starter Contactor Signal
1. Turn OFF the generator circuit breaker.
2. Reset the fault code detection system (See
Test 7 - Check Battery Components
“Resetting the Fault Code Detection System” on
1. Check the condition and electrical integrity of all page 17.).
wires, connectors, and cables throughout the
3. Gain access to the starter contactor. Connect
home standby unit. Some areas for particular
voltage meter to the terminals of the contactor.
focus are:
(Fig. 31).
• Battery connections
4. Select AUTO at the SYSTEM switch, then push
• Generator grounds, wiring, and connections and hold MANUAL-OVERIDE.
• Starter contactor 5. While the engine start cycle is in progress, the
2. Inspect the 15 Amp fuse. Replace if necessary. voltage reading should be 7-14 VDC.
NOTE: If the fuse is replaced, reset the fault code
detection system (See “Resetting the Fault Code
Detection System” on page 17.).
3. Attempt MANUAL start and observe system
operation.
4. Gain access to the CMA circuit board (See “How
to Access the CMA” on page 15.). Make sure all
wires and connectors are attached to the back of
the CMA board (See Fig. 29).

Fig. 31

NOTE: Remember that the CMA only delivers 12VDC to

the starter contactor for 15 seconds and then rests for 15
seconds.

Fig. 29 If no voltage is present at the coil terminals of the starter

5. Check the unit grounding cable (Fig. 30). contactor, go to Test 9.

Fig. 30
If electrical components are OK, go to Test 8.

Page 33
 Test 9 - Check CMA Board Output
1. Gain access to the CMA circuit board (See “How
to Access the CMA” on page 15.).
2. During the crank cycle, measure the voltage at Pin
#3, Wire #56 to ground (Fig. 32).
Test 10 - Check Starter
Refer to VANGUARD™ V-Twin OHV Repair Manual
(#272144) for procedures to check the condition of the
engine starter.

8
7
6
5
4
3
2
1

Fig. 32
If no voltage is measured at the CMA board, replace the
CMA/Control Panel.
2 If voltage is present at the CMA board, go to Step 3.

Fig. 33
3. Measure the voltage at the starter (Fig. 33). The
reading should be 7-14VDC at the starter terminal
and ground while cranking (the CMA will deliver
12VDC to the terminals of the starter contactor).
If voltage is present but the starter won’t engage, go to
Test 10.

Page 34
 (FC_5) Under Frequency & (FC_6) Over Frequency

Test 1
Measure no-load
and full-load
output frequency
at circuit breaker.

Test 2
Within
Measure frequency
Specs? Yes
on E1 & E2 at CMA

No

Within 2
Set engine RPM No Specs? Yes Replace CMA
to 62-62.5Hz at
no-load.
Retest No

Repair/Replace open
Within
wires E1 & E2 between
Specs?
CB output and CMA

Yes

Within
Specs? Yes END

No

Perform static
governor adjustment.

Fig. 34

Page 35
 (FC_5) Check No-Load Frequency
UNDER FREQUENCY 1. Remove the four screws that retain the circuit
breaker cover.
2. Reset the fault code detection system (See
The troubleshooting steps for under- and over-frequency “Resetting the Fault Code Detection System” on
faults are identical. Refer to Fig. 34 to troubleshoot page 17.).
(FC_5) & (FC_6) fault indications.
3. Set SYSTEM switch to AUTO, then push and hold
The low frequency shutdown feature is designed to MANUAL_OVERIDE to start the unit.
protect the generator and its loads from an output
4. Measure frequency at the generator side of the
frequency that is too low. The CMA senses frequency at
circuit breaker (Fig. 35).
Wire #s E1 and E2. If output frequency drops below 55 Hz
for three seconds, the CMA will shut down the generator.
The digital display will show FC_5 and the remote LED 62-62.5 Hz No Load should be measured.
will repeatedly flash five times with a pause. If the
system is equipped with the optional StatStation™
feature, “Under Frequency” will be displayed on the
Statstation screen.
Under frequency may be caused by:
• A restricted air filter
• A failure in the generator sense wiring (E1 or E2)
• A failed engine governor
• Problems with the fuel delivery system
• Excessive loads.
2 • A failure in the CMA
• An engine that is not producing sufficient power Fig. 35
If the no-load frequency is not correct, slowly turn the
governor adjustment screw ([A] Fig. 36) as required to
obtain a no-load frequency of 62.0 Hz - 62.5 Hz.
Test 1 - Check No-Load & Full-Load
Frequency
For the following procedures, we recommend the use of
Briggs & Stratton Tach and Hour meter (#19389) and
Briggs & Stratton Frequency Meter (#19543) with
Frequency Adapter (#19580).

CAUTION
Follow the manufacturer’s instructions for the type of
frequency meter you are using.

Perform the following tests under full electrical loads with

all gaseous fuel appliances turned ON and operating.
Fig. 36
No-Load RPM specification is 3750 ± 100 RPM / 62.0-62.5 Hz If frequency at no-load is correct, go to “Check Full-Load
Full-Load RPMspecification is 3420 ± 100 RPM / 57.0-62.5 Hz Frequency.”

Page 36
Check Full-Load Frequency
1. Make sure the generator circuit breaker is ON.
2. Remove utility power.
3. Measure frequency at the load side of the circuit
breaker (Fig. 37).
A least 57 Hz at Full Load should be measured.
Fig. 37
If the frequency is correct, restore utility power then
proceed to test 2.
If the frequency is not correct, slowly rotate the
adjustment screw until the frequency is above 57 Hz.
Then re-apply utility power.
NOTE: If a full-load frequency adjustment was required,
recheck the frequency at no load.
Test 2 - Measure Frequency at E1 & E2
1. Gain access to the generator control panel (See
“How to Access the CMA” on page 15.).
2. With the unit running, measure the frequency at
E1 and E2 at the CMA pins (Fig. 38).
Fig. 38
If the frequency is not correct, replace/repair the wiring
between the circuit breaker and E1 & E2 at the CMA.
Then re-test the frequency at E1 & E2.
If the frequency is correct but the generator continues to
shut down for low frequency, replace the CMA board.
(FC_6)
OVER FREQUENCY
The troubleshooting steps for under- and over-frequency
faults are identical. Refer to (Fig. 34) to troubleshoot
(FC_5) & (FC_6) fault indications.
Note that over-frequency is a symptom of a governor
related issue. Refer to VANGUARD™ V-Twin OHV Repair
Manual (#272144) for procedures to check the adjustment
and/or repair of the engine governor.
The CMA/Control Panel monitors generator output
frequency at Wire #s E1 and E2. If the generator output
frequency increases to 65Hz-70Hz, the CMA waits three
seconds before shutting the unit down. Should the
2
frequency exceed 70Hz, the CMA will shut down the
generator immediately. If the governor were to fail
entirely, the generator would shut down immediately
after starting.
The reason for the 5Hz latitude in frequency sensing is
that the engine governor will hunt somewhat before it
finds the desired setting. This causes variable frequency
outputs that are not harmful until they reach the 65Hz-
70Hz range.
If the CMA senses an over-frequency condition, the
digital display will show FC_6 and the remote LED will
repeatedly flash six times with a pause. If the system is
equipped with the optional Statstation™ feature, “Over
Frequency” will be displayed on the Statstation screen.
Page 37
 (FC_7)
High Temperature

Test 1
Check OTS
No OK? Yes END

Replace OTS
Shorted? Yes Reset Fault Detection
Start Unit

No

Test 2
Check Wire #95

Yes

Repair/replace
Shorted? Yes OK? No
Wire #95

No

Reset Fault Detection

Replace CMA OK? No
Start Unit

Yes

END
Fig. 39

Page 38
(FC_7) If no continuity is measured, the switch is good. Proceed
to Test 2.
HIGH TEMPERATURE
If continuity is found, replace the OTS.

The contacts of the Over Temperature Switch (OTS) are

normally open. If the engine oil reaches a critical
temperature, the switch contacts will close and complete Test 2 - Check Wire #95
a circuit to ground through Wire #95.
1. Gain access to the generator control panel (See
If the CMA senses this ground, it will shut down the “How to Access the CMA” on page 15.).
generator. The digital display will show FC_7 and the
2. Remove the 8-Pin connector from the CMA board.
remote LED will repeatedly flash seven times with a
pause. If the system is equipped with the optional 3. Measure for short-to-ground on Pin #5 Wire #95, as
Statstation™ feature, “High Oil Temperature” will be shown in Fig. 41.
displayed on the Statstation screen.

Common causes for high oil temperature include:

• Running the unit with the side doors removed
• Obstructed air inlet or exhaust port
• Debris in the engine cylinder cooling fins
Inspect for and correct any of these conditions before
checking the OTS. Once the problem is corrected, reset
the fault code detection system (See “Resetting the Fault
Code Detection System” on page 17.).

2
Test 1 - Check Over-Temperature Switch
Fig. 41
1. Select OFF at SYSTEM switch.
If a short-to-ground is measured, repair and/or replace
2. Remove the 15 Amp fuse. the wiring as necessary.
3. Remove Wire #95 (A) from the OTS as shown in If no short-to-ground is measured, replace the CMA.
Fig. 40. Make sure this wire does not touch
ground.
4. Test for continuity of the switch as shown.

Fig. 40

Page 39
 (FC_8)
TRANSFER SWITCH FAILURE

Transfer switch fault monitoring is an optional feature of

the Home Generator System, available on EMPOWER™
and INTELLIGEN™ series generator systems. A transfer
switch with a compatible Air Conditioning Control Module
(ACCM II) is required. This module monitors the transfer
switch during normal utility power and during standby
power. Not all transfer switches will have ACCM II.
A transfer switch failure indicates an open circuit within
the switch, which can occur:
• in the contactor coils
• in the limit switches
• at the fuse(s)
Because an open can occur in variable places, generator
symptoms may vary. A visual inspection is generally
sufficient to determine the source. Further trouble-
shooting can be done with a continuity tester and a
wiring diagram specific to the model of transfer switch
installed.
Note that the most common cause of transfer switch
failures is a blown fuse.
2
When a transfer switch failure occurs, the digital display
will show FC_8 and the remote LED will repeatedly flash
eight times with a pause. If the system is equipped with
the optional Statstation™ feature, “Transfer Switch
Failure” will be displayed on the Statstation screen.
• The FC_8 fail code will not display if a failure
occurs while the unit is running in EXERCISE,
MANUAL, or UTILITY mode.
• The fail code will display if a failure occurs while
the unit is stopped and set in AUTO mode.
• The unit will not shut down if a failure occurs
while the unit is delivering standby power. But the
fail code will display when power transfers back to
the utility.

Page 40
SECTION 3 - UNIT DISASSEMBLY

IMPORTANT: Prior to unit disassembly the unit must REMOVE THE EXHAUST BULKHEAD
be turned OFF, the 15 Amp fuse removed, the UTILITY
power removed, and the fuel system turned OFF.
1. Remove the air deflector from the top of the
muffler box ([A] Fig. 46).
REMOVING THE ACCESS DOORS

1. Unlock door ([A] Fig. 44).

Fig. 46
The exhaust bulkhead (B) is secured to the base of the
standby generator with three self-threading bolts ([C] Fig.
47) on each side of the bulkhead.
20k-59 20k-58

Fig. 44
2. Open door and lift from hinges ([B] Fig. 44).
3. Repeat for the remaining two doors.

REMOVE THE ROOF ASSEMBLY Fig. 47

2. Remove the six bolts and lift the exhaust bulkhead
The roof assembly is attached to the bulkheads on both from the floor of the generator enclosure (Fig. 48).
sides, as shown in (Fig. 45).
3
1. Remove the mounting hardware.
20k-21

Fig. 48

Fig. 45
2. Lift the roof from the generator and set aside.

Page 41
 REMOVE THE CONTROL PANEL 5. Disconnect Wires #92A and #93B from their
terminal spades ([H] Fig. 51) on the board.
BULKHEAD

Remove Battery
1. Disconnect the (-) negative battery cable ([A] Fig.
49).

Fig. 51
6. Disconnect Wire #22 ([I] Fig. 52), Wire #11 (J), Wire
#44 (K), Wire #0 (L), E1 and E2 (M) sensing wires,
and then disconnect the load-side wiring ([N] Fig.
52) from the circuit breaker.
Fig. 49
2. Disconnect the (+) battery cable.
3. Remove the battery and set aside.

Remove Control Panel And Breaker Cover

1. Remove the four screws (B) that secure the
control panel and the four screws that hold the
circuit breaker cover ([C] Fig. 50).

3
Fig. 52

Fig. 50
2. Remove the 8-pin connector ([D] Fig. 51) from the
control panel (CMA).
3. Disconnect the 2-pin (E) and 10-pin (F)
connectors.
4. Disconnect E1 and E2 (G) wires from the board.

Page 42
Disconnecting Automatic Voltage Regulator 4. Disconnect the fuel hose from the regulator
assembly, then remove the two mounting bolts
With the cables and wires disconnected from the circuit
([T] Fig. 56) that secure the regulator assembly.
breaker and the CMA,
1. Disconnect the wires at terminals 1, 2, 4, and 6 ([O]
Fig. 53).
2. Disconnect the wires at 0, 56, 11A, and 44A ([P]
Fig. 53).

20k-38

Fig. 56

NOTE: Cover openings in hose and regulator to prevent

Fig. 53 foreign material from entering equipment.

5. Remove the six remaining bolts ([U] Fig. 57) that

Disconnect Fuel Solenoid And Regulator secure the control panel bulkhead to the base and
1. Remove wire #14 and wire #0 ([Q] Fig. 54) from set aside.
solenoid and set harness aside.

3
Fig. 54 Fig. 57
2. With the wiring harness disconnected, gather the This exposes the generator and engine assembly (Fig.
remaining wires and push them through the 58).
grommets ([R] Fig. 55) in the panel bulkhead.
3. Remove the air duct ([S] Fig. 55) for easy access
to the fuel regulator bracket.

Fig. 55 Fig. 58

Page 43
 REMOVE THE MUFFLER ASSEMBLY REMOVE THE STATOR ASSEMBLY

1. Remove the tie wraps ([A] Fig. 61) that secure the
wire harness loom to the generator base.
CAUTION: When removing the hardware that
supports the muffler assembly, be sure to support the
weight of the muffler by hand.

1. Remove the bolts ([A] Fig. 59) that secure the

exhaust manifolds and gaskets.
2. Remove the bolts that secures the muffler support
brackets ([B] Fig. 59).

Fig. 61
2. Strip the loom from the harness and separate the
brush wires and earth ground from the stator
wires (Fig. 62).

Fig. 59
3. Slide the muffler over the engine oil dipstick and
remove.
4. Remove the mounting hardware on the right side.
5. Set muffler aside.

REMOVE COOLING DUCTS

3
Fig. 62
1. Remove the screws that secure the ducts to the 3. Remove the brush assemblies (B) and the ground
generator housing ([A] Fig. 60). wire (C) from the rear bearing carrier.(Fig. 63).

Fig. 60 Fig. 63

Page 44
 4. Disconnect the chassis ground wire ([D] Fig. 64). 7. Using an appropriate lifting device, raise the
generator as shown in ([H] Fig. 67) and slide a
wooden block under the alternator support
brackets ([I] Fig. 67).

64b

Fig. 64
5. Secure the crankshaft from turning (E) and break
the torque on the rotor through-bolt ([F] Fig. 65).

Fig. 67
62A
62B
CAUTION: Do not lift the entire engine/alternator/
base with this hook. Damage to the unit may occur.

8. Remove the stator through-bolts ([J] Fig. 68) and

align the stator wiring harness as shown in ([K]
Fig. 68).

Fig. 65
6. Remove the isolation mount bolts ([G] Fig. 66).
65a
65b

3
63

Fig. 68
9. Using a large deadblow hammer, strike the
flanges of the rear bearing carrier ([L] Fig. 69)
until it comes free of the stator. Remove the rear
Fig. 66

Page 45
 bearing carrier using care not to damage the
wiring harness ([M] Fig. 69).
11. With the weight of the stator still suspended, tap
against the upper lift lug ([O] Fig. 71) until enough
gap appears at the engine adapter casting ([P]
Fig. 71) to pry the stator free with a flat
screwdriver.

66b

67a
66a 67b

Fig. 69
10. Raise the generator assembly and reposition the
support block under the bolts at the end ([N] Fig
70) of the support brackets. This will lower the
alternator to a level position.

Fig. 71
12. Slide the stator straight off the rotor assembly
(Fig. 72).

68

Fig. 70

3 69

Fig. 72

Page 46
REMOVING THE ROTOR ASSEMBLY It should be recessed into the rotor shaft as
shown ([B] Fig. 75).

CAUTION! Rotor is heavy! Removal work must be

performed with care to avoid unexpected separation of
the rotor from the crankshaft.

Note: Use the tools included in Tool Kit #19590 to

perform removal of the rotor assembly. 72a

1. Apply cutting oil to lubricate the inside diameter of

the exposed rotor shaft. 72b
2. Using the 29/64” bit from the tool kit, drill straight
into the center of the rotor shaft to a depth of
about 1.5 inches (Fig. 73).
Fig. 75
7. Install the drive bolt ([C] Fig. 76) into the rotor
shaft until it bottoms on the push rod. Tighten the
bolt using an impact wrench, then strike the end
with a 4- to 5-lb. maul to break the rotor free of the
crankshaft taper.
70

73b
73a

Fig. 73
3. Remove all drill shavings with a small magnet.
4. Using the 1/2”-20 NF tap, thread the rotor shaft
([A] Fig 74) until 75% of the tap thread has been Fig. 76
turned in. DO NOT tap completely into rotor.
8. Carefully slide the rotor off the crankshaft (Fig.
77). Be careful not to damage the rotor windings
3
during this process.

74

Fig. 74
5. Clean the threads thoroughly.
6. Install the push rod from the tool kit and thread it
into the end of the engine crankshaft until it seats. Fig. 77

Page 47
 REMOVING THE ENGINE ADAPTOR

1. Loosen the bolts securing the alternator support

brackets to the bottom of the engine. Then
remove the two bolts ([A] Fig. 78) holding the
brackets to the engine adapter.
2. Remove the four bolts (B) that secure the adaptor
to the engine.

Fig. 78
3. Carefully remove the adaptor from the engine.

Page 48
SECTION 4 - SPECIFICATIONS & REFERENCE

GENERATOR SPECIFICATIONS

MODEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .040226 & 040227

RATED MAXIMUM POWER AND LOAD CURRENT (LPG) . . . . . . . . . . . . . . . . . . . . .20KW
AT 240 VOLTS 83.3 AMPS
AT 120 VOLTS 166.7 AMPS
RATED MAXIMUM POWER AND LOAD CURRENT (NG) . . . . . . . . . . . . . . . . . . . . . .18KW
AT 240 VOLTS 75 AMPS
AT 120 VOLTS 150 AMPS
RATED AC VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120/240 VOLTS
RATED FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 HZ AT 3600 RPM
PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SINGLE PHASE
POWER FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
NG FUEL SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 IN. W.C. (127-178MM)
LPG FUEL SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-14 IN. W.C. (279-356MM)
NORMAL OPERATING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-20°F (-28.8°C) -104°F (40°C)

RESISTANCE VALUES

ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.15-19.27 OHM

STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05-0.06 / 0.05-0.06 OHM
EXCITATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.77-0.94 OHM

FASTENER TORQUE VALUES

ENGINE ADAPTER TO ENGINE (CRISS-CROSS PATTERN). . . . . . . . . . . . . . . . . . .145-240 LB-IN

ALTERNATOR SUPPORT BRACKET TO ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . .240-350 LB-IN
ALTERNATOR SUPPORT BRACKET TO ENGINE ADAPTER . . . . . . . . . . . . . . . . . .240-350 LB-IN 4
ROTOR BOLT TO CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290-420 LB-IN
STATOR BOLTS FROM RBC TO ENGINE ADAPTER (CRISS-CROSS PATTERN) . .150-240 LB-IN
BRUSHES TO RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70 LB-IN
GROUND WIRE FROM HARNESS TO RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100 LB-IN

Page 49
 SCHEMATIC

Page 50
WIRING DIAGRAM

Page 51
4

Page 52