Briggs & Stratton 040298 Programmierhandbuch

Home Generator System

Manual 278994GS Rev. -

BRIGGS & STRATTON

SERVICE & TROUBLESHOOTING MANUAL

HOME GENERATOR SYSTEM - 7kW

Not for

Reproduction

FORWARD

This manual was written to assist technicians and service personnel with the repair and maintenance procedures for

Briggs & Stratton Home Standby Generators. 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 all engines and engine-driven systems. The

troubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate for the Briggs &

Stratton Home Standby Generators described herein. Alternative methods or procedures may pose risk to personal

safety and the safety and/or reliability of the engine 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.

No part of this manual 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.

This generator is rated in accordance with UL (Underwriters Laboratories) 2200 (stationary generator assemblies) and

CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators).

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Reproduction

SECTION 1 - Safety, Maintenance and Adjustments

SECTION 2 - Troubleshooting

SECTION 3 - Unit Disassembly

SECTION 4 - Generator Specifications

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Reproduction

THISPROPER SERVICE AND REPAIR IS IMPORTANT

TO THE SAFE, ECONOMICAL AND RELIABLE

MODELS COVERED IN THIS MANUAL

• 040298

• 040298A

• 040301

• 040315

• 040320

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Reproduction

SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS

Equipment Description

This product is intended for use as an optional residential

generator system which provides an alternate source of

electric power. This product does not qualify for emergency

standby as defined by NFPA 70 (NEC).

Every effort has been made to ensure that the information in

this manual is accurate and current. However, we reserve the

right to change, alter, or otherwise improve the product and

this document at any time without prior notice.

This repair manual contains safety information that is

designed to:

• Make you aware of hazards associated with

generators.

• Inform you of the risk of injury associated with

those hazards.

• Tell you how to avoid or reduce the risk of injury.

Signal Words in Safety Messages

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, could

result in minor or moderate injury.

NOTICE address practices not related to personal injury.

Safety Symbols and Meanings

WARNING Before attempting to service this

equipment, read and understand this manual and the

operating instructions of the generator. Failure to follow

instructions could result in property damage, serious

injury (including paralysis) or even death.

EXPLOSION FIRE ELECTRICAL

SHOCK

TOXIC FUMES ROTATING

PARTS

HOT SURFACE

AUTO START EXPLOSIVE

PRESSURE

CHEMICAL

BURN

LIFT HAZARD READ MANUAL

WARNING Running engines gives off carbon

monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache,

fatigue, dizziness, vomiting, confusion, seizures,

nausea, fainting, or death.

• Operate generator ONLY outdoors.

• Install a battery operated carbon monoxide alarm

near the bedroom.

• Keep exhaust gas from entering a confined area

through windows, doors, ventilation intakes, or

other openings.

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WARNING Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals

known to the State of California to cause cancer and

reproductive harm. Wash hands after handling.

WARNING The engine exhaust from this product

contains chemicals known to the State of California to

cause cancer, birth defects, or other reproductive harm.

WARNING Certain components in this product and

related accessories contain chemicals known to the State

of California to cause cancer, birth defects, or other

reproductive harm. Wash hands after handling.

WARNING Storage batteries give off explosive

hydrogen gas during recharging. Slightest spark

will ignite hydrogen and cause explosion. Battery

electrolyte fluid contains acid and is extremely

caustic. Contact with battery contents will cause

severe chemical burns. A battery presents a risk

of electrical shock and high short circuit current.

• DO NOT dispose of a battery in a fire. Recycle the

battery.

• DO NOT allow any open flame, spark, heat, or lit

cigarette during and for several minutes after

charging a battery.

• DO NOT open or mutilate the battery.

• Wear protective gloves, rubber apron, rubber boots,

and rubber gloves.

• Remove watches, rings, or other metal objects.

• Use tools having insulated handles.

WARNING Generators produce hazardous voltage.

Failure to properly ground generator can result in

electrocution. Failure to isolate generator from

utility power can result in death or injury to

electric utility workers due to back feed of

electrical energy.

• When using generator for backup power, notify

utility.

• DO NOT touch bare wires or bare receptacles.

• DO NOT use generator with electrical cords which

are worn, frayed, bare, or otherwise damaged.

• DO NOT handle generator or electrical cords while

standing in water, while barefoot, or while hands and

feet are wet.

• If you must work around a unit while it is operating,

stand on an insulated dry surface to reduce the risk

of a shock hazard.

• DO NOT allow unqualified persons or children to

operate or service generator.

• In case of accident caused by electrical shock,

immediately shut down the source of electrical

power and contact the local authorities. Avoid direct

contact with the victim.

• Despite the safe design of the residential generator,

operating the equipment imprudently, neglecting its

maintenance, or being careless can cause possible

injury or death.

• Remain alert at all times while working on this

equipment. Never work on the equipment when you

are physically or mentally fatigued.

• Before performing any maintenance on the

generator, disconnect the battery cable indicated by

a NEGATIVE, NEG or (-) first. When finished,

reconnect that cable last.

• After the system is installed, the generator may

crank and start without warning any time there is a

power failure. To prevent possible injury, always set

the generator’s system switch to OFF, remove the

service disconnect from the disconnect box, AND

remove the 15 Amp fuse BEFORE working on the

equipment.

Not for

Reproduction

NOTICE: Exceeding generator’s wattage/amperage capacity

can damage generator and/or electrical devices connected to

it.

• See Essential Circuits in operator’s manual.

• Start generator and let engine stabilize before

connecting electrical loads.

NOTICE: Improper treatment of generator can damage and

shorten its life.

• Use generator only for intended uses.

• If you have questions about intended use, contact

your authorized dealer.

• Operate generator only on level surfaces.

• Adequate, unobstructed flow of cooling and

ventilating air is critical to correct generator

operation.

• The access panels/doors must be installed

whenever the unit is running.

WARNING Propane and Natural Gas are extremely

flammable and explosive. Fire or explosion can

cause severe burns or death.

• Install the fuel supply system according to NFPA 37

and other applicable fuel-gas codes.

• Before placing the generator into service, the fuel

system lines must be properly purged and leak

tested.

• After the generator is installed, you should inspect

the fuel system periodically.

• NO leakage is permitted.

• DO NOT operate engine if smell of fuel is present or

other explosive conditions exist.

• DO NOT smoke around the generator. Wipe up any

oil spills immediately. Ensure that no combustible

materials are left in the generator compartment.

Keep the area near the generator clean and free of

debris.

WARNING Contact with the muffler area can result in

serious burns. Exhaust heat/gases can ignite

combustibles or structures causing a fire.

• DO NOT touch hot parts and AVOID hot exhaust

gases.

• Allow equipment to cool before touching.

• DO NOT install the generator closer than 5 feet

(1.5m) from any combustibles or structures with

combustible walls having a fire rating of less than 1

hour.

• Keep at least minimum distances shown in General

Location Guidelines to ensure proper generator

cooling and maintenance clearances.

• Replacement parts must be the same and installed in

the same position as the original parts.

WARNING Hazardous Voltage - Contact with power

lines can cause electric shock or burn. Lifting

Hazard / Heavy Object - Can cause muscle strain

or back injury.

• If lifting or hoisting equipment is used, DO NOT

contact power lines.

• DO NOT lift or move generator without assistance.

• DO NOT lift unit by roof as damage to the generator

will occur.

WARNING Starter and other rotating parts can

entangle hands, hair, clothing, or accessories.

• NEVER operate generator without protective

housings, covers, or guards in place.

• DO NOT wear loose clothing, jewelry, or anything

that may be caught in the starter or other rotating

parts.

• Tie up long hair and remove jewelry.

• Before servicing, remove 15 Amp fuse from control

panel and disconnect negative (-) battery cable.

CAUTION Installing the 15 Amp fuse could cause the

engine to start.

• Observe that the 15 Amp fuse has been removed

from the control panel for shipping.

• DO NOT install this fuse until all plumbing and wiring

has been completed and inspected.

CAUTION Excessively high operating speeds

increase the risk of injury and damage to the generator.

Excessively low speeds impose a heavy load on the

generator.

• DO NOT tamper with governed speed. Generator

supplies correct rated frequency and voltage when

running at governed speed.

• DO NOT modify generator in any way.

Not for

Reproduction

• DO NOT expose generator to excessive moisture,

dust, dirt, lint, or corrosive vapors.

• Remain alert at all times while working on this

equipment. Never work on the equipment when

you are physically or mentally fatigued.

• DO NOT start engine with air cleaner or air

cleaner cover removed.

• DO NOT insert any objects through cooling slots.

• DO NOT use the generator or any of its parts as a

step. Stepping on the unit can cause stress and

break parts. This may result in dangerous

operating conditions from leaking exhaust gases,

fuel leakage, oil leakage, etc.

• If connected devices overheat, turn them off and

disconnect them from generator.

• Shut off generator if electrical output is lost, if

equipment sparks, smokes, or emits flames, or if

unit vibrates excessively.

Generator Clearances

Install generator outdoors in an area which will not

accumulate deadly exhaust gas. DO NOT install generator

where exhaust gas could accumulate and enter inside or be

drawn into a potentially occupied building. Ensure exhaust

gas is kept away from any windows, doors, ventilation

intakes, or other openings that can allow exhaust gas to

collect in a confined area.

General Location Guidelines

• Install the unit outdoors ONLY.

• Place the unit in a prepared location that is flat

and has provisions for water drainage.

• Install the unit in a location where sump pump

discharge, rain gutter down spouts, roof run-off,

landscape irrigation, or water sprinklers will not

flood the unit or spray the enclosure and enter

any air inlet or outlet openings.

• Install the unit where it will not affect or obstruct

any services (including covered, concealed, and

underground), such as telephone, electric, fuel,

irrigation, air conditioning, and so forth.

• Install the unit where air inlet and outlet openings

will not become obstructed by leaves, grass,

snow, etc. If prevailing winds will cause blowing

or drifting, you may need to construct a

windbreak to protect the unit.

• Install the generator as close as possible to the

transfer switch and fuel supply to reduce the

length of wiring, conduit, and piping.

WARNING Running engines gives off carbon

monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache,

fatigue, dizziness, vomiting, confusion, seizures,

nausea, fainting, or death.

• Operate generator ONLY outdoors.

• Install a battery operated carbon monoxide alarm

near the bedroom.

• Keep exhaust gas from entering a confined area

through windows, doors, ventilation intakes, or

other openings.

WARNING Exhaust heat/gases can ignite

combustibles or structures causing a fire.

• DO NOT install the generator closer than 5 feet

(1.5m) from any combustibles or structures with

combustible walls having a fire resistance rating of

less than 1 hour.

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Reproduction

NOTICE: Laws or local codes may regulate the distance to the

fuel supply.

The minimum (MIN) clearances from aerial view of generator

(B) to combustible (D), and non-combustible (A) materials is

shown below.

• These distances are provided to give generator

clearances relative ONLY to combustibles,

generator cooling, and maintenance.

• The minimum distances in the figure are as

shown. All four sides of the generator cannot be

enclosed or restricted, even if the minimum

distances are maintained. DO NOT connect (A)

and/or (D) to (E).

• Do NOT install a roof over the generator, or place

the generator under an existing roof.

• Exhaust (C) must not be allowed to accumulate.

A- Non-Combustible material with Fire Resistant Rating of 1

hour or greater.

B- Home Standby Generator

C- Engine Exhaust

D-Combustible Material or Structure with a Fire Resistance

Rating of less than 1 hour.

E- Any structure or material. DO NOT connect (A) and/or (D)

to (E).

Lifting the Generator

The generator weighs more than 350 pounds (159 kg).

Proper tools, equipment, and qualified personnel should be

used in all phases of handling and moving the generator.

Lifting pockets are provided at each corner between the base

of the generator and its mounting pad. See Generator

Components for lifting pocket location. Retouch any chipped

paint with supplied touch-up paint.

WARNING Hazardous Voltage - Contact with power

lines can cause electric shock or burn. Lifting

Hazard / Heavy Object - Can cause muscle strain

or back injury.

• If lifting or hoisting equipment is used, DO NOT

contact power lines.

• DO NOT lift or move generator without assistance.

• DO NOT lift unit by roof as damage to the generator

will occur.

Not for

Reproduction

Access To The Generator

The 7kW Home Standby Generator System is equipped with

several access openings and a removable roof (Figure 1).

• Roof (A)

• Access Door (B)

• Side Panel (C)

• Access Panel (D)

• Access Cover for Oil Drain and Oil Filter (E)

Each generator is supplied with a set of identical keys. These

keys fit the locks that secure the access door.

Figure 1

Not for

Reproduction

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