Service & Troubleshooting - Technician Support

1. Press STOP/CONFIG on the controller.
2. Remove the 15 amp fuse from the controller (see your generator's installation and operator's manual for the fuse location). Is the fuse blown (the U-shaped wire between prongs is broken or damaged)?
   • Yes – Install a new fuse using only an identical 15 amp ATO fuse. Test again.
   • No – Go to step 3.
3. Inspect the battery for damage.
   • Check the battery posts for melting or damage caused by over-tightening.
   • Inspect the battery for discoloration, a raised top, or a warped or distorted case, which indicates that it has been frozen, overheated, or overcharged.
   • Inspect the battery case for leaks or cracks.
   • Do any of the above conditions exist?
     • Yes – Get a new battery. See the installation manual for the correct battery type and replacement size. Go to step 6.
     • No – Go to step 4.
4. Inspect the battery for correct installation and maintenance.
   • Verify correct polarity. The positive battery cable (red) must be connected to the positive battery (+) post, and the negative battery cable (black) must be connected to the negative battery (-) post.
   • Clean the cable clamps and battery terminals using a wire brush or sandpaper to remove oxidation or corrosion.
   • Inspect battery screws, clamps, and cables for breakage and loose connections. Replace and tighten if necessary.
   • Inspect the battery fluid level of unsealed batteries. If the fluid level is low, fill with distilled water only.
   • Do any of the above conditions exist?
     • Yes – Correct conditions as necessary. Go to step 5.
     • No – Go to step 5.
5. Disable the battery charger.
6. Disconnect the battery (A, Figure 11), and check the battery state of charge. Set the Digital Multimeter (B) to read DC volts. Place the red meter test lead (C) on the positive battery (+) post (D), and the black meter test lead (E) on the negative battery (-) post (F). Is the voltage less than 9.6 VDC or lower, between 10-12 VDC, or 12 VDC or higher?
   • 9.6 VDC or lower - Obtain a new battery. See the installation manual for proper battery type and replacement size. Go to step 7.
   • 10-12 VDC - Fully charge the battery. Go to step 7.
   • 12 VDC or higher - Go to step 7.

   
   Figure 11

7. Use an approved battery load tester to load test the battery. Does the battery pass the load test?
   • Yes – Proceed as follows:
     • If testing the original (used) battery, go to step 8.
     • If testing a new battery, go to Check Utility Voltage Input.
   • No – Obtain a new battery. See installation manual for proper battery type and replacement size. Repeat step 7.
     

   NOTICE - If you do not have an approved battery load tester, refer to the Battery Load Test section in the engine's repair manual (Part No. 80114787) for instructions on performing a battery load test without the battery load test tool.

8. Enable the battery charger.
9. Connect the battery and install the 15 amp fuse in the controller (see your generator's installation and operator's manual for fuse location). Turn on the PMD. Back probe the socket terminals of Pin 1 (-) and Pin 2 (+) (A, Figure 12) on the controller to measure DC voltage. Is the voltage at approximately 13.5 VDC with the charger on or more than 9.6 VDC without the charger on?
   • Yes – Go to Check Starter Relay Signal.
   • No – Go to step 10.

   NOTICE - Meter reading in steps 9 and 10 verify that utility voltage is present.

   WARNING - Even if the terminals of Pin 1 (-) and Pin 2 (+) are back-probed as instructed, avoid touching both terminals simultaneously. Do not remove socket terminals and probe the pins directly, because touching both pins with the same probe will result in arcing between terminals. Any arcing can damage controller components and wires, and cause eye injuries if safety glasses are not worn.

   WARNING - Fuel and fuel vapors can be ignited, causing explosion, which could result in death or serious injury.

   
   Figure 12

10. With the 2-pin connector plugged into the controller, measure DC voltage from Pin 2 (A, Figure 13) to the negative battery (-) post (B). Is the voltage at approximately 13.5 VDC with the charger on or more than 9.6 VDC without the charger on?
    • Yes – Go to step 12.
    • No – Go to step 11.

    
    Figure 13

11. Inspect all wiring and connections on the controller. Look for wires that are damaged (nicked, kinked, cut, abraded, burnt, broken, etc.), loose, or disconnected. Do any of these conditions exist?
    • Yes – Repair or replace as necessary. Test again.
    • No – Return to step 9.
12. Inspect the condition of all wires, cables, and connectors in the unit. Pay particular attention to ground posts and frame grounds. Look for wires that are damaged (nicked, kinked, cut, burnt, broken, etc.), loose, or disconnected. Do any of these conditions exist?
    • Yes – Replace or repair as necessary. Test again.
    • No – Go to Check Starter Relay Signal.

1. Connect the battery and install the 15 amp fuse (see your generator's installation and operator's manual for the fuse location). Turn on PMD. Set the Digital Multimeter (A, Figure 14) to read AC volts. Measure AC voltage at the utility connector (MAINS I/P Terminals 33 and 34) on the controller (B). Is approximately 240 VAC present?
   • Yes – Go to Check Trickle Charge at the Battery.
   • No – Go to step 2.

   
   Figure 14

2. Measure AC voltage on the bottom side of the two transfer switch fuses (A, Figure 15). Is approximately 240 VAC present?
   • Yes – Repair or replace the wiring between the transfer switch and generator. Test again.
   • No – Go to step 3.

   
   Figure 15

3. Measure AC voltage on the top side of the two transfer switch fuses (A, Figure 16). Is approximately 240 VAC present?
   • Yes – Remove the fuses and test for continuity (B). Replace the open fuse(s). Test again.

     NOTICE - Before replacing the fuses, turn off utility power and remove the fuses from the fuse holder and verify that no continuity to ground is present. If continuity to ground is present, check for wire shorts or a failed battery charger, warmer, or controller.

   • No – Repair or replace transfer switch wiring. Test again.

   
   Figure 16

NOTICE - If a new battery is installed during a utility outage, the charging circuit must be tested after restoration of utility power.

1. Set the Digital Multimeter (A, Figure 1) to read AC volts. Back probe pins L1 and L2 on the battery charger (Wires 16 and 17) (B). Is approximately 240 VAC present?
   • Yes – Go to step 2.
   • No – Go to Check Utility Voltage Input.

   
   Figure 17

2. Set the Digital Multimeter (B, Figure 18) to read DC volts. Connect the Digital Multimeter to the battery (A) by placing the red meter test lead (C) on the positive battery (+) post (D) and the black meter test lead (E) on the negative battery (-) post (F). Measure DC voltage across the battery terminals. Is voltage equal to or greater than 13.0 VDC?
   • Yes – Test again.
   • No – Go to step 3.

   
   Figure 18

3. Set the Digital Multimeter to read AC volts. Back probe pin 6 (Wire 44B) (A) and pin 14 (Wire 11B) (B) on the relay board. Is approximately 240 VAC present?

   NOTICE - The relay board on 13 kW units does not have the 3-pin connector shown in the following images.

   • Yes – Go to step 4.
   • No – Repair or replace Wire 44B (pin 6) and/or 11B (pin 14) between the generator and the relay board.

   
   Figure 19

4. Back probe pin 5 (Wire 16) and pin 13 (Wire 17) on the relay board. Is approximately 240 VAC present?
   • Yes –Go to Check Starter Relay Signal.
   • No – Repair or replace Wire 16 (pin 5) and/or Wire 17 (pin 13) between the battery charger and the relay board.

   
   Figure 20

1. Set the Digital Multimeter (A, Figure 21) to read DC volts. Remove Wire 56A from starter relay spade contact. Connect the positive (+) meter test lead (C) to Wire 56A (B), and connect the negative (-) meter test lead to ground (D).

   
   Figure 21

2. Install a 15 amp fuse in the controller (see your generator's installation and operator's manual for the fuse location).
3. Turn on the PMD.
4. Press START/SELECT on the controller to start the engine.
5. Measure DC voltage while the controller sends the crank signal (approximately 10 seconds ON and 10 seconds OFF for two minutes). Is the voltage equal to or greater than 9.6 VDC?
   • Yes – Alternately check for the same DC voltage at the positive (+) (A, Figure 22) and negative (-) (A, Figure 23) posts of the starter relay while Wire 56A has voltage. Is VDC present on both sides of the starter relay?
     • Yes – Go to Check Starter Solenoid Connection.
     • No – Install a new starter relay. Test again.
   • No – Less than 9.6 VDC. Go to Check Battery Voltage Supply.
   • No - No voltage. Go to Check Controller Output.
   • Check the ground condition through the base of the solenoid.

     
     Figure 22
     
     
     Figure 23

1. Is the battery voltage at the positive post of the starter relay (A, Figure 24) equal to or greater than 9.6 VDC?
   • Yes – Go to step 2.
   • No – Repair or replace the wiring and/or connections between the battery and starter relay. Test again.

   
   Figure 24

2. Connect the positive (+) meter test lead to the battery cable connection (A, Figure 25) at the starter relay. Connect the negative (-) meter test lead to ground.

   
   Figure 25

3. Press START/SELECT on the controller to crank the engine.
4. Is DC voltage equal to or greater than 9.6 VDC?
   • Yes – Check that the engine spins freely and is not locked up. If the engine spins freely, install a new starter. Test again.
   • No – Repair or replace the main battery wiring between the starter and starter relay. Test again and go to Check Controller Output.

1. Is the battery voltage at the positive (+) post of the starter solenoid (A, Figure 26) equal to or greater than 9.6 VDC?
   • Yes – Go to step 2.
   • No – Refer to the Starter Motor Solenoid Voltage Test section in the engine's repair manual (Part No. 80114787) for further testing. Repair or replace the wiring and/or connection

   
   Figure 26

2. Is the battery voltage on Wire 2 (A, Figure 27) at the starter relay (Wire 97 on some models) equal to or greater than 9.6 VDC?
   • Yes – Go to step 3.
   • No – Go to Check Battery Voltage Supply.

    

3. Disconnect the control wire 1 (Wire 98 on some models) (A, Figure 28) from the spade contact at the starter solenoid (B). Connect the positive (+) meter test lead (C) to the control wire (A), and connect the negative (-) meter test lead (D) to ground (E).

   
   Figure 28

4. Install a 15 amp fuse at the controller (see your generator's installation and operator's manual for the fuse location).
5. Turn on the PMD.
6. Press START/SELECT on the controller to crank the engine.
7. Is DC voltage on the control wire at the starter solenoid equal to or greater than 9.6 VDC?
   • Yes – Check that the engine spins freely and is not locked up. If the engine spins freely, install a new starter. Test again.
   • No – Repair or replace the wiring between the starter relay and the starter solenoid. Test again and go to Check Controller Output.

At the Controller

1. Connect the positive (+) meter test lead (A, Figure 29) to Terminal 4 (Dig OP B, Wire 56B) (B). Connect the negative (-) meter test lead (C) to Terminal 1 (Wire 0B) (D).

   
   Figure 29

2. Turn on the PMD.
3. Install a 15 amp fuse at the controller (see your generator's installation and operator's manual for the fuse location).
4. Press START/SELECT on the controller to crank the engine.
5. Is DC voltage on Pin 1 and Pin 4 equal to or greater than 9.6 VDC?
   • Yes – Go to step 6 to measure the voltage into and out of the relay board.
   • No – Less than 9.6 VDC. Less than 9.6 VDC. Go toCheck Battery Voltage Supply.
   • No -No voltage. Install a new controller. Test again.

   At the Relay Board

6. Back probe Pin 9 (Wire 56B) (A, Figure 30) on the relay board with the red meter test lead (B) and connect the other meter test lead (C) to ground (D). Is the DC voltage equal to or greater than 9.6 VDC?

   NOTICE - The relay board on 13 kW units does not have the 3-pin connector shown in the following images.

   • Yes – Go to step 7.
   • No – Repair or replace Wire 56B between the relay board (Pin 9) and the controller. Test again.

   
   Figure 30

7. Back probe Pin 8 (Wire 56A) (A, Figure 31) on the relay board with the red meter test lead 9 (B) and connect the other meter test lead (C) to ground (D). Is the DC voltage equal to or greater than 9.6 VDC?
   • Yes – Go to Symptom: Engine Does Not Start.
   • No – Repair or replace Wire 56A between the relay board (Pin 8) and the starter solenoid. Test again.

   
   Figure 31

1. Locate and reset the E-Stop switch
2. Acknowledge/ Clear Alarm at the Controller
3. Re-test

Confirm the green E-Stop jumper wire is installed on terminal block pins 6 and 7

1. Is the 15 amp ATO type fuse installed in the controller?
   • Yes – Go to step 2.
   • No – Install the 15 amp ATO type fuse in the controller.
2. Is the generator controller set to AUTO?
   • Yes – Go to Service Call & Maintenance Best Practices.
   • No – Press AUTO/MANUAL on the controller. An LED illuminates to indicate that the system is in AUTO mode.

NOTICE - If a fault is present on the controller, go to GC-1030 Series Controller Alarms & Event Log and review the corresponding fault displayed on the controller.

1. Check that the engine has been filled to the correct level with the recommended oil. Is the oil at the correct level?
   • Yes – Go to Change Engine Oil and Filter.
   • No – Slowly add oil until the correct oil level is reached. DO NOT OVERFILL.

1. Use one wrench to hold the hex on the oil drain hose fitting (to prevent rotation), and use a second wrench to remove the drain plug.
2. Drain the oil into a suitable container.
3. Install the drain plug back into the oil drain hose fitting.
4. Rotate the oil filter in a counter-clockwise direction to remove it from the oil filter adapter.
5. Check that the old gasket is not stuck to the oil filter adapter and that the gasket surface is clean and dry.
6. Install a film of clean engine oil to the gasket of a new oil filter.
7. Install the oil filter by hand until the gasket contacts the oil filter adapter.
8. Tighten the oil filter an additional 1/2-3/4 turn.
9. Remove the fill cap and fill the engine with the correct quantity and type of oil.
   • Quantity (Dry Engine):
     • 12-13 kW (M38): Add 42-45 ounces (or 1.31-1.41 quarts).
     • 17-26 kW (M61): Add 78-80 ounces (or 2.44-2.5 quarts).
   • Type: – Use only API SJ/CF 5W-30 synthetic oil. Select the best viscosity for the outdoor temperature range expected. DO NOT use special additives.
10. Install the fill cap.
11. Install the 15 amp fuse in the controller (see your generator's installation and operator's manual for the fuse location).
12. Push and hold START/SELECT on the controller to start the engine.
13. Let the engine run for one minute and check for leaks.
14. Press OFF on the controller to stop the engine.
15. Wait a minimum of five minutes for the engine to cool and to allow the oil to drain back to the oil pan.
16. Check the engine oil level as follows:

    NOTICE - The most accurate oil level readings are obtained when the engine is cold.

    • Remove the dipstick and wipe it dry with a clean, lintfree cloth.
    • Slowly insert the dipstick into the dipstick tube.
    • Check that the dipstick is fully installed in the dipstick tube.
    • Wait a minimum of ten seconds and then slowly remove the dipstick.
    • Check that the oil level on the dipstick is at or near the top of the crosshatch pattern (A, Figure 83).
      

      NOTICE - Check the oil level on both sides of the dipstick.

    • The lower level of the two readings is the correct oil level measurement.

       

    • If necessary, remove the oil fill cap and slowly add oil. DO NOT OVERFILL.
    • Install the dipstick and oil fill cap.
17. Push and hold START/SELECT on the controller to start the engine. Check for leaks while the engine runs.
18. Let the engine run for a minimum of one minute.
19. Push and hold STOP/CONFIG on the controller.
20. Return to step 15. Repeat the steps if necessary until the engine oil level is correct.
21. Remove the 15 amp fuse from the controller (see your generator's installation and operator's manual for the fuse location).

NOTICE - Dispose of used oil and the oil filter at a proper waste disposal or recycling center.

Figure 83

1. Is sufficient fuel available in the fuel supply tank?

   NOTICE - Fuel is only present on units with a liquid propane (LP) supply tank.

   • Yes – Go to step 2.
   • No – Replenish the fuel supply.
2. Are the main fuel supply valve and any in-line fuel shutoff valves open?
   • Yes – Go to Check Fuel Pressure.
   • No – Open the main fuel supply valve and any in-line fuel shutoff valves.

1. Remove the roof and front panel.
2. For 13 kW units only: press the fuel selector toggle switch (A, Figure 3) that is located on the top of the field connection box to the correct position -- LP or NG (B).

   
   Figure 3

3. Locate the main jet (A, Figure 4) and idle jet (B) on the engine. The number of turns counter-clockwise of each jet from a fully-seated position (0 turns) indicates whether the unit is configured to run on NG or LP. The jet settings for NG and LP are as follows:

   12-13kW NG and LP Configurations
   Model	Engine	Frequency	Fuel Type	Main Jet Turns	Idle Jet Turns
   12kW	BSPP 38 v/s	60 Hz	NG	1/2	2-1/2
   			LP	0	1/4
   13kW	BSPP 38 v/s	60 Hz	NG	1-3/8	3/8
   			LP	1/8	3/4

   
   Figure 4

4. The engine of your generator system is factory-calibrated and set to operate on NG. To convert to either fuel, do the steps that follow:
   • Locate the controller.
   • Press STOP/CONFIG to navigate to Manual Mode.
   • Press and hold the STOP/CONFIG button to access the configuration menu.
   • Press START/SELECT to enter Write Mode to edit the items in the configuration menu.

     NOTICE - If you are changing the setup in the generator's controller from the factory setting of NG fuel to LP fuel you will need to enter the configuration menu by using the Dealer Password, which is available on the Power Portal.

   • Navigate to the “SELECT PROFILE” page, press START/SELECT 3 times to access the profile selection row for the generator, and press START/SELECT once you have set the correct profile. For example “13KW_LP” for operating a 13kW unit running on LP fuel.

     NOTICE - Selecting a profile that is not intended for the generator can cause the generator to run erratically and can result in damage.

   • To save the new fuel setting, press and hold the STOP/CONFIG button until “Saving Settings…” is displayed.
   • For 13 kW Units: DO NOT change the fuel regulator setting. Whether you are using NG or LP fuel this setting MUST be left at the factory setting of NG (A, Figure 5).

Figure 5

1. Open the roof and remove the air inlet side end cap.
2. Locate the fuel selector valve (A, Figure 7) on top of the fuel pressure regulator (B). To convert to either type of fuel, do the steps that follow:

   
   Figure 7

   • Set the fuel selector. For LP, rotate the lever on the fuel selector valve until LP is aligned with “OUT” on the fuel regulator. For NG, rotate the lever clockwise 90° so the handle position of the lever will be up and down and the “NG” letters will be on the left.
   • For 17, 20, and some 26 kW PowerProtect units, locate the fuel selector switch (A, Figure 8) and select either LP or NG. For 18, 22, and some 26 kW PowerProtect units, locate the fuel selector switch (A, Figure 9) and select either LP or NG.

     
     Figure 8
     
     Figure 9

   • Locate the controller.
   • Press STOP/CONFIG to navigate to Manual Mode.
   • Press and hold the STOP/CONFIG button to access the configuration menu.
   • Press START/SELECT to enter Write Mode to edit the items in the configuration menu.

     NOTICE - If you are changing the setup in the generator's controller from the factory setting of NG fuel to LP fuel you will need to enter the configuration menu by using the Dealer Password, which is available on the Power Portal.

   • To set up the generator’s controller for LP fuel, enter the configuration menu by using the dealer password, which is available on the Power Portal. Navigate to “select profile” and push “select” on the correct profile for the generator. For example, choose “20KW_LP” for operating a 20kW unit running on LP fuel.

     NOTICE - Selecting a profile that is not intended for the generator can cause the generator to run erratically and could result in damage.

   • To save the new fuel setting, push and hold the STOP/CONFIG button until “Saving Settings…” displays.

NOTICE - The generator inlet fuel pressure should be 11-14 inches WC (LP) or 3.5-7 inches WC (NG).

1. Close the main fuel supply valve to stop the flow of fuel to the generator.
2. Locate the installer-supplied fuel pressure test port closest to the generator (A, Figure 32).

   NOTICE - If a test port does not exist, see the appropriate installation manual for instructions on installing it. To proceed with troubleshooting in the absence of a test port, go to step 4 of Check Fuel Solenoid and Thermal Fuses to use the test port in the fuel pressure regulator (B, Figure 32). Although use of this port will indicate whether fuel is present, it will not indicate whether the incoming fuel has dropped in pressure.

3. Obtain an analog manometer (C, Figure 32). Remove the test port plug and install the manometer.
4. Open the main fuel supply valve to start the flow of fuel to the generator.
5. Inspect the manometer gauge. Is the generator inlet fuel pressure 11-14 inches WC (LP) or 3.5-7 inches WC (NG).
   • Yes – Go to Check Fuel Solenoid and Thermal Fuses.
   • No – Repair or replace fuel delivery system. Test again.

NOTICE - No more than 0.5 inches WC drop should be seen between static and dynamic fuel pressure and the fuel reading should be stable.

Figure 32

1. Locate the fuel solenoid. For 13 and 17-26 kW PowerProtect generator units, the fuel solenoid (A, Figure 33) is located inside the unit on the fuel regulator assembly (B).

   
   Figure 33

2. Set the Digital Multimeter (A, Figure 34 and 35) to read DC volts.
   • For 12 kW and 17 or 20 kW Fortress II units, disconnect the 2-pin connector (B, Figure 34) from the fuel solenoid (C). Connect the positive (+) meter test lead (D) to the socket terminal of Wire 14C (E) and connect the negative (-) meter test lead (F) to ground (Wire 0D) (G).

     
     Figure 34

   • For 13 kW and 17-26 kW PowerProtect units, the fuel solenoid is part of the fuel regulator assembly. Disconnect the 2-pin connector (B, Figure 35) from the assembly (C).Connect the positive (+) meter test lead (D) lead to the 2-pin connector (D) and connect the negative (-) meter test lead (E) to ground (F).

     
     Figure 35

3. Measure DC Volts at the fuel solenoid while the engine is cranking. Is the voltage equal to or greater than 9.6 VDC?
   • Yes – Go to step 4.
   • No –Go to step 6.

   NOTICE - There will not be voltage at the pauses between cranks. When activated, a "click" is heard at the fuel solenoid and that indicates that it opened correctly.

4. Set your Digital Multimeter to read ohms.
5. Measure the pin-to-pin coil resistance on the fuel solenoid. Is the resistance close to 11 ohms?
   • Yes – Go to step 6.
   • No – Install a new fuel solenoid. Test again.
6. Remove the pipe plug from the fuel pressure regulator test port and install an analog manometer.
7. Verify that the fuel supply valves are open.

   NOTICE - Step 8 applies only to Fortress II generator units. If you do not have a Fortress II unit, skip to step 10.

8. Disconnect the 2-pin connector (A, Figure 36) at the fuel solenoid (B). Connect the jumper wire (C) from the positive battery (+) post (D) to the fuel solenoid.

   
   Figure 36

9. Check the manometer gauge: Is the fuel pressure at 11-14 inches WC (LP) or 3.5-7 inches WC (NG)?
   • Yes – Go to step 10.
   • No – Low fuel pressure. Repair or replace the fuel delivery system. Test again.
   • No - No fuel pressure Install a new fuel solenoid. Test again.
10. For PowerProtect units, connect the 2-pin connector (Wires 14C and 0D) at the fuel solenoid.
11. Connect the positive (+) meter test lead (A, Figure 37) to Terminal 5 (Dig O/P C, Wire 14A) (B) on the controller. Connect the negative (-) meter test lead (D) to ground (E).

    
    Figure 37

12. Measure DC volts while cranking. Is the voltage equal to or greater than 9.6 VDC?
    • Yes – Repair or replace Wire 14 between the controller and fuel solenoid. Test again and go to step 13.
    • No – Install a new controller. Test again and go to step
13. Back probe Pin 11 (Wire 14A) (A, Figure 38) on the relay board with the red meter test lead (B) in and connect the other meter test lead (C) to ground (D). Is the DC voltage equal to or greater than 9.6 VDC?

    NOTICE - The relay board on 13 kW units does not have the 3-pin connector shown in the following images.

    • Yes – Go to step 14.
    • No – Repair or replace Wire 14A between the relay board (Pin 11) and the controller. Test again.

    
    Figure 38

14. Back probe Pin 10 (Wire 14B) (A, Figure 39) on the relay board with the red meter test lead (B) and connect the other meter test lead (C) to ground (D). Is the DC voltage equal to or greater than 9.6 VDC?
    • Yes – Yes - Go to Check Fuel Pressure Regulator.
    • No – Repair or replace Wire 14B between the relay board (Pin 10) and the fuel solenoid. Test again.

Figure 39

1. Loosen the bolts holding the regulator to the base.
2. Install a barbed 1/8-inch NPT fitting into one of the two atmospheric pressure ports in the fuel pressure regulator. Attach a 24-inch length of hose to the fitting.
3. Install an analog manometer to the fuel pressure regulator test port.
4. Disconnect Wire 14C (A, Figure 40) at the 2-pin connector of the fuel solenoid (B). Connect the jumper wire (C) from the positive battery (+) post (D) to the fuel solenoid.
5. Cover the open atmospheric pressure port with your index finger and very gently blow into the hose. Does the manometer show a decrease in pressure?
   • Yes – Go to Check Spark.
   • No – Install a new fuel pressure regulator. Test again.

     NOTICE: When the fuel solenoid is energized (open) with battery voltage, the applied pressure allows fuel to pass through the fuel pressure regulator. Do not use compressed air, as the fuel pressure regulator diaphragm is easily ruptured.

Figure 40

Removal

1. Remove the plastic knob or disengage the two retaining clips to release the air filter cover (A, Figure 92).
2. Remove thumb nut (B, Figure 92) from threaded rod.
3. Remove the metal retainer plate (C, Figure 92).
4. Remove and discard the air filter element (D, Figure 92).
5. Thoroughly clean the air filter mount (E, Figure 92), metal retainer plate (C), and air filter cover (A) of any dust, dirt, or debris.

Figure 92

Installation

1. Put a new air filter element (D, Figure 92) onto the air filter mount (E).
2. Fit the metal retainer plate (C, Figure 92) evenly and tightly into the air filter element.
3. Install the thumb nut (B, Figure 92) onto the threaded rod and tighten until tight.
4. Install the air filter cover (A, Figure 92).
5. Install the plastic knob or engage the two retaining clips to secure the air filter cover (A, Figure 92).

1. Obtain two Ignition Testers (D in Specialty Tools).
2. Remove spark plug cables from the spark plug terminals.

   NOTICE - Always pull on the boot at the terminal end of the cable. Pulling on the cable can result in damage.

3. Install the free end of the spark plug cables onto the tester prongs. Install the tester alligator clips onto the good engine grounds.

   WARNING - Be sure there is no fuel or fuel vapors present, which, if spark-ignited, can cause a fire or explosion resulting in death or serious injury.

4. Press START/SELECT on the controller to start the engine.
5. Is spark present?
   • Yes – Ignition is functioning properly. Go to step 6.
   • No – Verify the spark tester is properly installed and repeat steps 4-5. If spark is still not present, install a new ignition coil, following instructions in the appropriate engine service manual. Test again.
6. Press STOP/CONFIG on the controller and remove the 15 amp fuse (see your generator's installation and operator's manual for the fuse location) or shut off the PMD.
7. Remove the tester alligator clips from the engine grounds and install on the spark plug terminals.
8. Install a 15 amp fuse in the controller and press START/ SELECT to start the engine.
9. Is spark present?
   • Yes – The ignition is operating properly. Go to Check the Crankcase Vacuum.
   • No – Go to step 10.
10. Fully clean the area around the spark plugs to keep debris out of the combustion chamber. Remove the spark plugs from the cylinder heads with a 5/8-inch spark plug socket, and then continue as follows:
    • Check that the spark plug type is Champion XC92YC or RC12YC. Refer to your generator's operator's manual for the proper spark plug.
    • Check that the spark plug is in good condition.
    • Check that the spark plug gap is 0.020 inches (0.508 mm) for vertical units and 17 and 20 kW Fortress II units or 0.030 inches (0.762 mm) for 17, 18, 20, 22, and 26 kW PowerProtect units.
    • Are all of the above conditions observed?
      • Yes – Go to Check the Crankcase Vacuum.
      • No – Install a new spark plug(s). Test again.

1. Obtain a digital vacuum gauge.
2. Remove the dipstick.
3. Insert the vacuum gauge tube into the dipstick tube.

   NOTICE - The vacuum gauge must fit tightly. On 12-13 kW units, the dipstick tube also serves as the oil fill neck, so wrap the vacuum gauge tube with paper towels as needed to achieve a tight fit.

4. Press START/SELECT on the controller to start the engine.
5. Is the vacuum gauge reading -5 to -10 inches WC?
   • Yes – Go to Check and Adjust Valve Clearance.
   • No – See the appropriate Engine Service Manual.

   NOTICE - If necessary, call Briggs & Stratton Technical Support for assistance.

NOTICE - For the best results, check valve clearance when the engine is cold.

1. Remove the spark plug cables from the spark plug terminals. Always pull on the boot at the terminal end or damage to the cable can occur.
2. Thoroughly clean the area around spark plugs to keep dirt out of the combustion chamber.
3. Remove spark plugs from cylinder heads using a 5/8- inch spark plug socket.
4. Turn the engine crankshaft in the direction of engine rotation until the piston of cylinder #1 is at top dead center (TDC) of the compression stroke.
5. To ensure that the tappet is not resting on the compression release ball, insert a TDC tool (or wooden dowl or chopstick) into the spark plug hole and slowly turn the crankshaft in the same direction until the piston has moved 0.25 inches (6.0 mm) down the bore past TDC.
6. Remove the 4 screws with washers to release the valve cover.
7. Insert a feeler gauge between the rocker arm and intake valve stem. Verify that the intake valve clearance is 0.004-0.006 inches (0.102-0.152 mm).
8. If adjustment is necessary, proceed as follows:
   • Obtain a Briggs & Stratton Valve Adjustment Set (E in Specialty Tools).
   • Place the socket (13 mm hex) over the locknut.
   • While holding the socket on the locknut, insert the hex (5 mm) or Torx (T-40) bit through the hold to engage the adjuster screw.
   • Rotate the socket counter-clockwise to loosen the locknut and slightly turn the adjuster screw in a clockwise or counter-clockwise direction (to either reduce or increase the valve clearance, respectively).
   • While holding the hex or Torx (T-40) bit on the adjuster screw to prevent rotation, turn the socket in a clockwise direction to tighten the locknut.
   • Remove your tools and use the feeler gauge to check valve clearance. Repeat steps as necessary until the proper valve clearance is obtained.
   • Tighten the locknut to 70 in-lbs (8 Nm). Check the valve clearance one more time to verify that the adjusting screw did not move when the locknut was torqued.
9. Insert the feeler gauge between the rocker arm and exhaust valve stem. Verify that the exhaust valve clearance is 0.007-0.009 inches (0.178-0.229 mm). If adjustment is necessary, repeat step 8.
10. For big block engines, start 4 screws with washers to install the valve cover of cylinder #1. For small block engines, start 2 screws with washers.
11. Alternately tighten valve cover screws to 70 in-lbs (8 Nm) using a crosswise pattern.
12. Repeat steps 4-11 on cylinder #2.
13. Install spark plugs into cylinder heads and finger tighten until snug. Tighten spark plugs to 180 in-lbs (20 Nm) using a spark plug socket.
14. Install spark plug cables onto spark plug terminals.
15. Press START/SELECT on the controller. Does the engine start?
    • Yes, but the engine does not shut off or the "FAIL TO STOP" alarm is present - Go to step 16.
    • Yes - Go to Check the Voltage.
    • No - Go to Check Fuel Supply Pressure.
16. Shut off the fuel supply valve, check that the voltage is removed from Wire 14A and Wire 14B from the fuel solenoid, and test for fuel pressure. Is fuel pressure present?
    • Yes - Replace the fuel regulator solenoid assembly. Go back to step 15.
    • No - Go to Check Fuel Solenoid and Thermal Fuses.

See Generator Runs Rough

NOTICE - General images are shown and may not match your unit. Load side voltage testing may be done on the LOAD side of the breaker or a pre-wired terminal block.

1. Locate the generator circuit breaker and remove the breaker cover plate.
2. Verify that the generator circuit breaker is in the ON (Closed) position.
3. Install a 15 amp fuse in the controller, if removed (see your generator's installation and operator's manual for the fuse location).
4. Set the Digital Multimeter (A, Figure 41) to read AC volts. Press START/SELECT on the controller to start the engine. Is 240 VAC present at the load side of the circuit breaker or terminal block?
   • Yes - Go to Measure Generator Voltage at the Controller.
   • No - Go to Measure Circuit Breaker Line-Side Voltage.

Figure 41

1. With the engine running, back probe the socket terminals with one meter test lead (A, Figure 42) on Pin 29 (Wire 44C) (B) and the other meter test lead (C) on Pin 30 (Wire 11C) (D) and at the back of the controller. Is 240 VAC present?
   • Yes - Install a new controller. Test again.
   • No - Repair or replace Wire 44C (Pin 29) and/or Wire 11C (Pin 30) (Refer to Wiring Diagrams). Test again.

Figure 42

NOTICE - General images are shown and may not match your unit. Line side voltage testing may be done on the LINE side of the breaker or a pre-wired terminal block.

1. Locate the generator circuit breaker and remove the breaker cover plate (if not already removed).
2. Make sure that the generator circuit breaker is in the OFF (Open) position.
3. Push START/SELECT on the controller to start the engine. With the engine running, back probe the socket terminals with one meter test lead (A, Figure 43) on the L2 contact (B) and the other meter test lead (C) on the L1 contact (D) on the side of the controller. Is there 240 VAC at the line side of the circuit breaker?
   • Yes – Manually cycle the circuit breaker. Test again. If the problem continues, install a new circuit breaker. Test again.
   • No – Go to Generator Does Not Produce Voltage.

Figure 43

See Generator Does Not Produce Start section

Refer to applicable Service Bulletin and AVR Firmware sections below

See the instructions above, found in the Measure Circuit Breaker Load-Side Voltage section.

Removal

1. Locate the AVR (Figure 78) behind the controller.
2. Remove the screws to release the generator controller plate.
3. Disconnect stator Wires 11A and 11D, Wires 44A and 44D, Wires 22A, 22b, and 22C, and DEP Wires 2 and 6 from the respective terminals on the AVR.
4. Disconnect rotor Wires 1 and 4 from the AVR.
5. Disconnect the field flash Wire 56C from the AVR.
6. Disconnect RS485 8-pin connector J44 from the AVR.
7. Disconnect the CAN 2-pin connector Wires 113 and 114 from the AVR.
8. Disconnect DC Wires 13D, 13F, 0B, and 0C from the AVR.
9. Remove the AVR from the standoffs. Discard the AVR in accordance to local codes.

Installation

NOTICE - Always hold the AVR by the outside edges only. Avoid touching components, as electro static discharges can damage circuits and sensitive electronic components.

1. Place a new AVR onto the standoffs.
2. Connect stator Wires 11A and 11D, Wires 44A and 44D, Wires 22A, 22b, and 22C; and DEP Wires 2 and 6 to the respective terminals on the AVR.
3. Connect rotor Wires 1 and 4 to the AVR.
4. Connect the field flash Wire 56C to the AVR.
5. Connect RS485 8-pin connector J44 to the AVR.
6. Connect CAN 2-pin connector Wires 113 and 114 to the AVR.
7. Connect DC Wires 13D, 13F, 0B, and 0C to the AVR.

Figure 78

See the instructions above, found in the Measure Circuit Breaker Load-Side Voltage section.

See the Check Frequency steps, found in the Generator Does Not Produce Voltage > Symptom: Improper Frequency, or Electronic Governor issues section.

See the instructions above, found in the Replace AVR section.

1. Press START/SELECT on the controller to start the engine. Let 10 seconds go by so the engine can pressurize. Is a low oil pressure condition indicated?
   • Yes - Go to step 2.
   • No - Go to Check for High Engine Temperature.
2. Is the engine oil level low?
   • Yes - Add oil until the level is at or near the top of the crosshatch pattern on the dipstick. Test again.
   • No - Go to Check Low Oil Pressure Switch for Short to Ground.

NOTICE - The normally closed contacts of the switch are held open by engine oil pressure when the engine is running. If oil pressure drops below 7-10 psi, the contacts close to complete a circuit to ground on Wire 85, and the engine shuts down.

1. Press START/SELECT on the controller.
2. Remove the 15 amp fuse from the controller (see your generator's installation and operator's manual for the fuse location) or turn off the PMD.
3. Disconnect Wire 85 from the Low Oil Pressure switch.
4. Set the Digital Multimeter (A, Figure 60) to read continuity. Measure for short to ground by connecting one meter test lead (B) to Wire 85 (C) and the engine block and connecting the other meter test lead (D) to ground (E). Is short to ground present?
   • Yes - Repair or replace wiring. Test again.
   • No - Go to Check Low Oil Pressure Switch for Continuity.

Figure 60

1. Disconnect Wire 85 from the Low Oil Pressure switch if installed.
2. Install the 15 amp fuse in the controller if removed (see your generator's installation and operator's manual for the fuse location).
3. Press START/SELECT on the controller to start the engine and allow 10 seconds to elapse for the engine to pressurize.
4. Set the Digital Multimeter (A, Figure 61) to read continuity. Check continuity to ground at the switch spade contact by connecting one meter test lead (B) to the engine block (C) and the other meter test lead (D) to ground (E). Is continuity to ground present?

   NOTICE - The switch may be tested using a hand or vacuum pump (Briggs & Stratton part number: 19493) or equivalent, applying either vacuum or pressure.

   • Yes - The switch contacts are closed. Go to Check Engine Oil Pressure.
   • No - The switch contacts are open. Install a new controller. Test again.

Figure 61

1. Disconnect Wire 85 (A, Figure 62) from the Low Oil Pressure switch (B).
2. Remove the Low Oil Pressure switch and install a suitable oil pressure gauge.
3. Install the 15 amp fuse in the controller (see your generator's installation and operator's manual for the fuse location).
4. Press START/SELECT on the controller to start the engine.
   • Yes - Install a new Low Oil Pressure switch. Test again.
   • No - See the service manual for your engine.

NOTICE - If necessary, call Briggs & Stratton Technical Support for assistance.

Figure 62

1. Install a 15 amp fuse in the controller, if removed (see your generator's installation and operator's manual for the fuse location).
2. Press START/SELECT on the controller to start the engine. Let the engine run for 5 minutes. Is a high engine temperature condition indicated?
   • Yes - Go to step 3.
   • No - Perform Final Checks.
3. Check for these most common causes of high engine temperature: low engine oil level, obstructed air inlet, obstructed exhaust outlet, debris in the engine compartment, deteriorated foam seals, or the roof or side panels are not installed. Are any of these conditions observed?
   • Yes - Correct as necessary. Test again.
   • No - Go to Check High Engine Temperature Switch for Short to Ground.

NOTICE - The switch contacts are normally open. If the engine temperature goes above 300°F, +/- 7°F (149°C, +/- 4°C), the contacts close to complete a circuit to ground on Wire 95 and the engine will shut down.

1. Press STOP/CONFIG on the controller.
2. Remove the 15 amp fuse from the controller (see your generator's installation and operator's manual for the fuse location) or turn off the PMD.
3. Disconnect Wire 95 from the High Engine Temperature switch.
4. Set the Digital Multimeter (A, Figure 63) to read continuity. Measure for short to ground by connecting one meter test lead (B) to Wire 95 and the engine block (C) and the other meter test lead (D) to ground (E). Is short to ground present on Wire 95?
   • Yes - Repair or replace the wiring. Test again.
   • No - Go to Check High Engine Temperature Switch for Continuity.

Figure 63

1. Connect Wire 95 to the High Engine Temperature switch.
2. Install a 15 amp fuse in the controller (see your generator's installation and operator's manual for the fuse location).
3. Press START/SELECT on the controller to start the engine.
4. Set the Digital Multimeter (A, Figure 64) to read continuity. With the engine cold or below normal operating temperature, check for continuity between terminals of the High Engine Temperature switch by connecting one meter test lead (B) to one prong of the switch (C) and the other meter test lead (D) to the other prong of the switch (E). Is continuity present?
   • Yes - Install a new High Engine Temperature switch. Test again.
   • No - Install a new controller. Test again.

   
   Figure 64

5. Go to Generator Runs Rough.

Observe engine “air cooling fan” foam seal, replace.

Observe engine Air Filter, replace if necessary.

Understanding the way the National Electrical Code looks at the home (specifically NFPA 70 Section 220 Service Load Calculations) is the first step to confirm a generator is sized properly for a dwelling. Follow the basic steps below to confirm fuel pressure is sufficient, and the installed generator is sized correctly for the demand/ amp load.

1. Use voltmeter amp clamp to measure home/ site amperage demand, at the ATS and/or main breaker panel.
2. Use a sizing calculator to determine the proper generator size. Does the generator size match the sizing calculation?
   • Yes - Fuel pressure may be insufficient when the generator is loaded down. Go to Check Fuel Supply Pressure.
   • No - Go to Install power management components, or replace generator.

An increase in demand can occur when homeowners add higher amperage load items after a generator is installed. Visit the Briggs & Stratton Power Academy and complete one of the “Residential Sizing and Power Management” courses to learn more about Briggs & Stratton Symphony Power Management System, and proper generator sizing to help homeowners understand what options are available to correct this type of overload or unbalanced load scenario.

Access the Power Academy

1. Get two Ignition Testers (D in Specialty Tools).
2. Remove the spark plug cables from the spark plug terminals.

   NOTICE - Pull on the boot at the terminal end of the cable. Do not pull on the cable, as it can cause damage.

3. Install the free end of the spark plug cables (A, Figure 65) onto the inline tester prongs (B). Install the tester alligator clips onto the spark plug terminals (C).

   WARNING - Make sure there is no fuel or fuel vapors present, which, if spark ignited, can cause a fire or explosion resulting in death or serious injury.

4. Get a Digital Tachometer and Hour Meter (B in Specialty Tools) (D, Figure 65) and install it on one side of the engine as follows:
   • Insert solder lug of the white wire (E) under the engine or the frame bolt (F) for a suitable ground connection.
   • Tightly coil the red wire (G) over an insulated section of the spark plug cable (H) three to four times.

   NOTICE - Keep wires away from hot or moving engine parts.

5. Get a screwdriver with an insulated handle (J, Figure 65) and a jumper wire with an alligator clip on both ends (K).
6. On the side of the engine opposite the tachometer, attach a jumper wire (K, Figure 65) to the shank of the screwdriver (J) and to the engine lifting eye (L) or another suitable ground.
7. Press START/SELECT on the controller to start the engine.
8. Check the tachometer and write down the engine RPM with both cylinders functioning.
9. Touch the offset prong on the ignition tester with the end of the screwdriver to the ground out cylinder (A, Figure 65).
10. Check the tachometer and write down the engine RPM with only one cylinder functioning.
11. Press STOP/CONFIG on the controller.
12. Remove the tachometer (D, Figure 65) and the jumper wire (K).
13. Repeat steps 4-12 on the second cylinder.

    
    Figure 65

14. Compare the test results. After an initial drop, did each cylinder get back up to 3600 RPM?

    NOTICE - There should not be more than a 75-RPM difference between each cylinder.

    • Yes - The cylinders are doing an equivalent amount of work. The engine function is satisfactory.
    • No - The cylinder with the low RPM is not doing what it should. See the appropriate Engine Service Manual.

NOTICE - If necessary, call Briggs & Stratton Technical Support for assistance.

1. Obtain a digital vacuum gauge.
2. Remove the dipstick.
3. Insert the vacuum gauge tube into the dipstick tube.

   NOTICE - The vacuum gauge tube must fit tightly. On 12-13 kW units, the dipstick tube is also the oil fill neck, so wrap the vacuum gauge tube with paper towels as needed to achieve a tight fit.

4. Activate the vacuum gauge.
5. Press START/SELECT on the controller to start the engine.
6. Is the vacuum gauge showing -5 to -10 inches WC?
   • Yes - Perform Final Checks.
   • No - See the service manual for your engine.

NOTICE - If necessary, call Briggs & Stratton Technical Support for assistance.

NOTICE - General images are shown and may not match your unit. Load side voltage testing may be done on the LOAD side of the breaker or a pre-wired terminal block.

1. Locate the generator circuit breaker and remove the breaker cover plate.
2. Verify that the generator circuit breaker is in the ON (Closed) position.
3. Install a 15 amp fuse in the controller, if removed (see your generator's installation and operator's manual for the fuse location).
4. Set the Digital Multimeter (A, Figure 41) to read AC volts. Press START/SELECT on the controller to start the engine. Is 240 VAC present at the load side of the circuit breaker or terminal block?
   • Yes - Go to Measure Generator Voltage at the Controller.
   • No - Go to Measure Circuit Breaker Line-Side Voltage.

Figure 41

1. With the engine running, back probe the socket terminals with one meter test lead (A, Figure 42) on Pin 29 (Wire 44C) (B) and the other meter test lead (C) on Pin 30 (Wire 11C) (D) and at the back of the controller. Is 240 VAC present?
   • Yes - Install a new controller. Test again.
   • No - Repair or replace Wire 44C (Pin 29) and/or Wire 11C (Pin 30) (Refer to Wiring Diagrams). Test again.

Figure 42

NOTICE - General images are shown and may not match your unit. Line side voltage testing may be done on the LINE side of the breaker or a pre-wired terminal block.

1. Locate the generator circuit breaker and remove the breaker cover plate (if not already removed).
2. Make sure that the generator circuit breaker is in the OFF (Open) position.
3. Push START/SELECT on the controller to start the engine. With the engine running, back probe the socket terminals with one meter test lead (A, Figure 43) on the L2 contact (B) and the other meter test lead (C) on the L1 contact (D) on the side of the controller. Is there 240 VAC at the line side of circuit breaker?
   • Yes - Manually cycle the circuit breaker. Test again. If the problem continues, install a new circuit breaker. Test again.
   • No - Go to Test 16: Check the Alternator Rotor Winding Resistance.

Figure 43

NOTICE - 12VDC from the crank circuit is applied to terminal 56 on the Smart AVR. That 12VDC is sent through the AVR and out to the positive brush lead #4.

1. Locate the Smart AVR and remove Wire 56.
2. Set the Digital Multimeter to read DC volts.
3. Connect one meter test lead to Wire 56 and the other meter test lead to a proper engine ground. Is the voltage approximately 12 VDC?
   • Yes – Go to Check Alternator Rotor Winding Resistance.
   • No – Troubleshoot the wiring connection from AVR back to Starter Relay. Go to Engine Does Not Crank, found in the Generator Does Not Start section.

NOTICE - General images are shown and may not match your unit. Locate the appropriate locations for each of the wires listed. Additional panels may need to be removed.

1. Locate the generator circuit breaker and remove the breaker cover plate (if not already removed).
2. Set the Digital Multimeter (A, Figure 44) to read ohms.
3. For both horizontal units (B, Figure 44) and vertical units (C), connect one meter test lead (D) to Wire 11 (E) and the other meter test lead (F) to Wire 22 (G). Measure the resistance and write down the results.

   
   Figure 44

4. Connect one meter test lead (A, Figure 45) to Wire 22 (B) and the other meter test lead (C) to Wire 44 (D). Measure the resistance and write down the results.

   
   Figure 45

5. Compare the results obtained in steps 2-3. Based on meter quality, the readings should have approximately less than one ohm (with no more than one ohm) of difference between the windings. Are these your observations?
   • Yes - Go to step 6.
   • No - Low resistance indicates a shorted stator winding, while high resistance or infinity (OL) is an open in the power winding. A new stator is needed. Contact Briggs & Stratton Technical Support to receive prior authorization before installing a new stator. Test again.
6. Connect one meter test lead (A, Figure 46) to Wire 11 (B) and the other meter test lead (C) to a proper engine ground (D). Measure the resistance and write down the results.

   
   Figure 46

7. Connect one meter test lead (A, Figure 47) to Wire 44 (B) and the other meter test lead (C) to a proper engine ground (D). Measure the resistance and write down the results.

   
   Figure 47

8. Is a reading of infinity (OL) obtained in steps 6-7?
   • Yes - Connect Wire 11 and Wire 44 to the circuit breaker. Connect Wire 22 to a neutral lug. Go to Test Stator Excitation Windings.
   • No - Stator winding is shorted to ground. A new stator is needed. Contact Briggs & Stratton Technical Support to receive prior authorization before installing a new stator. Test again.

NOTICE - General images are shown and may not match your unit. Locate the appropriate locations for each of the wires listed. Additional panels may need to be removed.

1. Locate the generator circuit breaker and remove the breaker cover plate (if not already removed).
2. Set the Digital Multimeter (A, Figure 48) to read ohms.
3. Connect one meter test lead (B, Figure 48) to Wire 2 (C) and the other meter test lead (D) to Wire 6 (E). Is the resistance 1-2 ohms?
   • Yes - Go to step 4.
   • No - Low resistance indicates a shorted stator excitation winding, while high resistance or infinity (OL) is an open in the excitation winding. A new stator is needed. Contact Briggs & Stratton Technical Support to receive prior authorization before installing a new stator. Test again.

   
   Figure 48

4. Connect one meter test lead (A, Figure 49) to a stator power winding (either Wire 11 or Wire 44) (B) and the other meter test lead (C) to an excitation winding (either Wire 2 or Wire 6) (D). Is a reading of infinity (OL) seen?
   • Yes - Go to step 5.
   • No - Stator power winding shorted to excitation winding. A new stator is needed. Contact Briggs & Stratton Technical Support to receive prior authorization before installing a new stator. Test again.

   
   Figure 49

5. Connect one meter test lead (A, Figure 50) to a stator excitation wire (either Wire 2 or Wire 6) (B) and the other meter test lead (C), to an applicable engine ground (D). Is a reading of infinity (OL) seen?
   • Yes - Go to Check Rotor Resistance Through Brush Wires.
   • No - Stator excitation winding shorted to ground. A new stator is needed. Contact Briggs & Stratton Technical Support to receive prior authorization before installing a new stator. Test again.

   
   Figure 50

If the previous tests within Check Alternator Rotor Winding Resistance have been completed and the resistance test results are still inconclusive, a megohmmeter (or Megger) test may be necessary.
NOTICE - If you do not have a Megger, go to Check Rotor Resistance Through Brush Wires.

NOTICE - Prior to conducting the megohmmeter test, disconnect all stator leads and the controller and AVR wires.

1. Follow the instructions of the megohmmeter manufacturer.
2. Apply 500 VDC to any stator lead and the stator frame. Write down the results.
3. Repeat step 2 on every stator lead until each coil has been tested. Write down the results.
4. If any reading is less than 0.5 megohm (500 kOhms), current flow to ground is likely. Repair or replace the stator.

NOTICE - A reading of 0.5 megohm (500 kOhms) or higher indicates a functional stator.

NOTICE - The rotor resistance can be measured through the brush wires (Wire 1 and Wire 4). This eliminates the need for further disassembly, but can result in a reading that is slightly higher than the specification. See Check DC Amperage in Perform AVR Bypass if the measurement is not within 10% of specification.

1. Connect one meter test lead (B, Figure 51) to a brush wire (Wire 1) (C) and the other meter test lead (D) to the other brush wire (Wire 4) (E).

   
   Figure 51

2. Measure the rotor resistance. Is the resistance 8-25 Ohms?

   NOTICE - Refer to the Alternator Resistance Chart for exact resistance values for your generator unit.

   • Yes - Go to step 4.
   • No - A very low resistance can indicate a shorted rotor. A reading of infinity or a very high resistance can indicate that there is an open circuit or a partially open condition in the rotor windings. Go to step 3.

    

   Alternator Resistance Chart
   HSB Power Node	Winding Resistance (ohms)
   	Rotor	Stator (Power WIndings)	Stator (DPE)
   12kW	Wires (+) - (-): 11.767 - 14.381	Wires 11-44: 0.144 - 0.176	Wires Z1-Z2: 0.387 - 0.473
   13kW	Wires (+) - (-): 11.767 - 14.381	Wires 11-44: 0.144 - 0.176	Wires Z1-Z2: 0.387 - 0.473
   17kW	Wires 1-4: 16.2 - 23.5	Wires 11-44: 0.10 - 0.12	Wires 2-6: 0.77 - 0.94
   18kW	Wires 1-4: 9.43 - 10.09	Wires 11-44: 0.106 - 0.109	Wires 2-6: 0.932 - 0.947
   20kW	Wires 1-4: 16.2 - 23.5	Wires 11-44: 0.10 - 0.12	Wires 2-6: 0.77 - 0.94
   22kW	Wires 1-4: 9.43 - 10.09	Wires 11-44: 0.106 - 0.109	Wires 2-6: 0.932 - 0.947
   26kW	Wires 1-4: 11.01 - 12.05	Wires 11-44: 0.065 - 0.075	Wires 2-6: 0.946 - 0.97

    

3. Disassemble the generator if necessary to gain access to the rotor slip rings (A, Figure 52). Connect the meter test leads (B and C) to the slip rings. Is the resistance between slip rings 8-25 Ohms?

   NOTICE - Refer to the Alternator Resistance Chart for exact resistance values for your generator unit.

   • Yes - Repair or replace the brushes and/or wiring. Test again and go back to step 2.
   • No - Install a new rotor. Test again and go back to step 2.

   NOTICE - Under certain loading conditions, oxide or brush deposits can accumulate on slip rings causing an increase in electrical resistance. If resistance is high, remove the brushes and clean the slip rings with an applicable surface-conditioning product, such as a 3M Scotch-Brite Hand Pad. Do not use sandpaper or an emery cloth, as abrasive particles will embed in the slip rings and brushes.

   
   Figure 52

4. Connect one meter test lead (A, Figure 53) to either brush wire (Wire 1 or Wire 4) (B) and the other meter test lead (C) to an applicable engine ground (D). Is a reading of infinity (OL) seen?
   • Yes - Go to Perform AVR Bypass Tests.
   • No - Rotor winding shorted to rotor shaft. Install a new rotor. Test again.

   
   Figure 53

1. Press STOP/CONFIG on the controller and remove the 15 amp fuse (see your generator's installation and operator's manual for the fuse location).
2. Set the generator circuit breaker to the OFF (Open) position.
3. Set the Digital Multimeter (A, Figure 54) to read AC voltage.
4. Connect the jumper wire (B, Figure 54) from Wire 4 (C) to the positive battery (+) post (D). Connect another jumper wire (E) from Wire 1 (F) to the negative battery (-) post (G).

   NOTICE Installing a 5 amp in-line fuse on the jumper wire between the battery and Wire 4 is recommended.

5. Install the 15 amp fuse in the controller.
6. Connect one meter test lead (H, Figure 54) to Wire 6 (J) and the other meter test lead (K) to Wire 2 (L).

   WARNING - Utility Voltage is present at the controller. Avoid contact with any bare wires. Use caution to avoid personal injury and/or equipment damage.

7. Press START/SELECT on the controller to start the engine.
8. Measure AC voltage across Wire 2 and Wire 6. Referencing the table below, write down the value that best describes your results.

    

   Wires 2 and 6
   AC Voltage	Zero	< 100	≥ 100
   NOTE: The left carrot symbol (<) means "less than" and the underlined right carrot symbol (≥) means "equal to or greater than".

    

9. Press STOP/CONFIG on the controller.

   
   Figure 54

10. Leave the battery jumper wires connected (A, Figure 55) and connect one meter test lead (B) to Wire 11A (C) and the other meter test lead (D) to Wire 44A (E).
11. Press START/SELECT on the controller to start the engine.
12. Measure the AC voltage across Wire 11A and 44A. Referencing the table below, write down the value that describes your results.

     

    Wires 11 and 44A
    AC Voltage	Zero	< 120	≥ 120
    NOTE: The left carrot symbol (<) means "less than" and the underlined right carrot symbol (≥) means "equal to or greater than".

     

13. Press STOP/CONFIG on the controller.

    
    Figure 55

NOTICE - The Check DC Amperage test should only be conducted if BOTH the power and excitation winding tests fail to meet specifications. If the power and winding excitation winding tests show acceptable results, there is no need to conduct DC amperage testing.

NOTICE - The exact amperage readings may vary depending on ambient temperature, battery voltage, meter calibration, etc.

1. What will be used for the DC amperage check?
   • Digital Multimeter - Go to step 2.
   • DC Amp Clamp Meter (Recommended) - Go to step 3.
2. Digital Multimeter. Do the steps that follow:
   • Set the Digital Multimeter (A, Figure 56) to read DC amperage. Move the red test lead to the 10 amp post on the multimeter.
   • Disconnect the jumper wire between the negative battery (-) post and Wire 1.
   • Make sure a jumper wire (B, Figure 56) is still connected from Wire 4 to the positive battery (+) post (C).
   • Connect one meter test lead to the negative battery (-) post and the other meter test lead (D, Figure 56) to Wire 1 (E).
   • Measure the static amp draw and write down the results.
   • Go to step 4.

   
   Figure 56

3. DC Amp Clamp Meter. Do the steps that follow:
   • Set the DC amp clamp meter (A, Figure 57) to read DC amperage. See the amp clamp meter instruction manual for details.
   • Capture Wire 1 (B, Figure 57) in the jaw of the meter. Measure the static amp draw and write down the results.

   NOTICE - For accurate results, make sure the wire is in the center of the meter.

4. Press START/SELECT on the controller to start the engine.
5. Measure the DC amperage. Referencing the table that follows, write down the value that describes your results.

   NOTICE - Current, measured in amperes, in a circuit can be calculated by using Ohm's Law. Voltage divided by resistance (ohms) equals current (amps). The equation is I = V/R. For example, if the voltage (V) of a circuit equals 12 volts and the resistance in ohms (R) equals 12 ohms, then by using the equation, there is 1 amp (I) (12V/12R = 1I).

   NOTICE - Normal readings are 1.0-1.5 amps (12-13 kW) or 0.6-0.75 amps (17-26 kW).

   DC Amperage
   12-13 kW Unit	Zero	Low	1.0 - 1.5	High
   17-26 kW Unit	Zero	Low	0.6 - 0.75	High

6. Press OFF on the controller and remove the 15 amp fuse.
7. Disconnect the jumper wire (D, Figure 57) between the positive battery (+) post (E) and Wire 4 (C).
8. If connected, disconnect the jumper wire (G, Figure 57) between the negative battery (-) post (F) and Wire 1 (B).

   
   Figure 57

9. Using the table that follows, find the column (A-G) that matches the values you wrote down for steps 8 and 12 in the Check AC Voltage test and step 5 in this test. Replace the component indicated. Test again.

   NOTICE - Contact Briggs & Stratton Technical Support to receive prior authorization before installing a new rotor or stator.

   NOTICE - It may be necessary, but not required, to replace the AVR when a new stator is installed.

   NOTICE - < is "less than"; > is greater than"; ≥ is "greater than or equal to".

   Smart AVR
   DC Amperage	A		B		C		D	E	F		G
   Wires 2 and 6	≥ 100		≥ 100		< 100		Zero	< 100	< 100		High
   Wires 11A and 44A	≥ 120		< 120		≥ 120		Zero	< 120	< 120		< 120
   DC Amperage (12-13kW | 17-26kW)	1.0-1.5	0.6-0.75	1.0-1.5	0.6-0.75	1.0-1.5	0.6-0.75	Zero or Low	High	1.0-1.5	0.6-0.75	Zero
   Replace	AVR		Stator		Stator		Rotor	Rotor	Stator		Rotor or Stator

10. Press START on the controller. Does the engine have correct voltage?
    • Yes - Go to Perform System Start-up and Final Controller Checks , found in the Installation & Start-up Support section.
    • No - Return to the beginning of Generator Does Not Produce Voltage.

NOTICE - If you reach this point of the diagnostics twice, call Briggs & Stratton Technical Support for further instructions.

Action: (refer to applicable Service Bulletin and AVR Firmware sections below)

NOTICE - General images are shown and may not match your unit.\

1. Locate the generator circuit breaker and remove the breaker cover plate (if not already removed).
2. Install a 15 amp fuse in the controller if removed (see your generator's installation and operator's manual for the fuse location).
3. Set the generator circuit breaker to the OFF (Open) position.
4. Push START/SELECT on the controller to start the engine.
5. Set the Digital Multimeter to read frequency (A, Figure 58). Connect the meter test leads (B and C, Figure 58) to the breaker (D). Is 60 Hz present at the line side of the circuit breaker?
   • Yes - Go to step 6.
   • No - Go to Check the Electronic Governor.

   NOTICE - 180 Hz is not possible. Check the meter or use a tiny tachometer to check engine RPMs.

   
   Figure 58

6. Obtain a Digital Tachometer and Hour Meter (B in Specialty Tools). Install as follows:
   • Insert the solder lug of the white wire under the engine or frame bolt for suitable ground.
   • Tightly coil the red wire over an insulated section of the spark plug cable, using three to four turns. Go to step 7.

   NOTICE - Keep wires away from hot or moving engine parts.

7. Back probe the socket terminals by connecting one meter test lead (A, Figure 59) to Pin 29 (GENSET I/P Y, Wire 44C) (B) and the other meter test lead (C) to Pin 30 (GENSET I/P R, Wire 11C) (D) at the back of the controller. Is 60 Hz present?
   • Yes (and it is displayed on the controller LCD) - Go to Generator Runs Rough.
   • Yes (but it is NOT displayed on the controller LCD) - Install a new controller. Test again.
   • No - Repair or replace the wiring between the circuit breaker and the controller. Test again.

Figure 59

1. Press STOP/CONFIG on the controller and remove the 15 amp fuse (see your generator's installation and operator's manual for the fuse location).
2. Perform a sweep test (see the controller's Operation Manual for instructions). Does the stepper motor shaft move freely without sticking?
   • Yes - Resistance testing of the stepper motor windings is required. Disconnect the electronic governor from the controller and go to step 3.
   • No - Inspect the stepper motor and linkages for any binding or interference with bulkhead engine components. Repair or replace as necessary. Test again.
3. Disconnect the connector from the controller and set the Digital Multimeter to read ohms. Place one meter test lead on Terminal 1 (Wire 8 - Yellow) and the other on Terminal 2 (Wire 9 - Black). Is resistance around 40 ohms?
   • Yes - Go to step 4.
   • No - Inspection of the wires between the stepper motor and controller is needed. Disconnect the electronic governor from the controller and go to step 4.
4. Place one meter test lead on Terminal 3 (Wire 10 - Blue) and the other on Terminal 4 (Wire 12 - White). Is resistance around 40 ohms?
   • Yes - Install a new controller. Return to step 1 and test again. If you return to this point, go to step 5.
   • No - Repair or replace Terminal 3 (Wire 10 - Blue) and/or Terminal 4 (Wire 12 - White). Test again.
5. Can an engine idle speed of 3600 RPM be obtained?
   • Yes - Go to Generator Runs Rough.
   • No - See the appropriate Engine Service Manual.

NOTICE - If necessary, call Briggs & Stratton Technical Support for assistance.

Using the up/down arrows on the GC-1030 Series Controller, navigate to the MAINS screen and determine the MAINS status. Does the Controller display MAINS FAILED?

1. Yes - Go to Check Utility Voltage Input (ATS Wiring & Fuses only).
2. No - The generator may be in a Weekly Exercise or 45 Minute Burn Off.

1. Measure AC voltage on the bottom side of the two transfer switch fuses (A, Figure 15). Is approximately 240 VAC present?
   1. Yes - Repair or replace the wiring between the transfer switch and generator. Test again.
   2. No - Go to step 3.
      

      
      Figure 15

2. Measure AC voltage on the top side of the two transfer switch fuses (A, Figure 16). Is approximately 240 VAC present?
   1. Yes - Remove the fuses and test for continuity (B). Replace the open fuse(s). Test again.
      

      NOTICE - Before replacing the fuses, turn off utility power and remove the fuses from the fuse holder and verify that no continuity to ground is present. If continuity to ground is present, check for wire shorts or a failed battery charger, warmer, or controller.

   2. No - Repair or replace transfer switch wiring. Test again.

      
      Figure 16

Potential Root Cause(s): 

Loss of alternator output voltage is present or the controller is not recognizing the output voltage.

Potential Root Cause(s): 

Wire 57 (I/P: ANLG TEMP/DIG G) is not connected either on controller or relay board.

Potential Root Cause(s): 

Ambient temperature is below 40 degrees Fahrenheit.

Potential Root Cause(s): 

Controller does not recognize the AVR (CANbus) or the AVR is failing.

Potential Root Cause(s): 

Voltage at controller Terminals 1 and 2 is greater than 15 VDC (shutdown alarm).

Potential Root Cause(s): 

Voltage at controller Terminals 1 and 2 is less than 10 VDC (warning alarm).

Potential Root Cause(s): 

Jumper is removed from generator Terminals 11 and 12, Wires 100A and/or 100B are removed from Terminals 11 and 12 and/or the relay board (E-Stop Terminals 1 and 2), Wire 100C is obstructed between relay board Terminal 3 (E-Stop) and controller Terminal 25 (Pin 9, I/P: ANLG FL/DIG H).

Potential Root Cause(s): 

Too much load is being put on the generator.

Potential Root Cause(s): 

The generator does not start after pressing the START/SELECT button on the controller a number of times.

Potential Root Cause(s): 

The generator does not stop after pressing STOP/CONFIG on the controller.

Potential Root Cause(s): 

The generator does not start after pressing the START/SELECT button on the controller a number of times.

Potential Root Cause(s): 

Engine block exceeds around 300 degrees Fahrenheit, engine seals (for air-flow) are eroded, air flow is blocked, continuity between terminals on the switch is failing (cold engine), or Wire 95 (Dig I/P E) is touching ground.

Potential Root Cause(s): 

Voltage generated during the auto exercise is too high. Recreate the exercise and monitor the voltage at the generator circuit breaker.

Potential Root Cause(s): 

Generator unit is low on oil, no oil pressure is present, the oil filter is clogged, a bad oil psi switch is present (continuity to ground with psi present), or Wire 85 (Dig I/P D) is touching ground.

Potential Root Cause(s): 

Voltage generated during the auto exercise is too low. Recreate the exercise and monitor the voltage at the generator circuit breaker.

Potential Root Cause(s): 

Voltage generated during the auto exercise is too low. Recreate the exercise and monitor the voltage at the generator circuit breaker.

Potential Root Cause(s): 

Exceeded the maintenance alarm setpoint (either hours of generator run time or the set due date). Enter configuration to reset the maintenance alarm.

Potential Root Cause(s): 

Exceeded the maintenance alarm setpoint (either hours of generator run time or the set due date). Enter configuration to reset the maintenance alarm.

Potential Root Cause(s): 

Frequency exceeds 60 Hz at the line side of the circuit breaker and/or the controller.

Potential Root Cause(s): 

Frequency exceeds 60 Hz at the line side of the circuit breaker and/or the controller.

Potential Root Cause(s): 

Engine speed exceeds 4,200 RPM at the controller.

Potential Root Cause(s): 

Voltage between Terminal 30 (R) and the L1 contact on the circuit breaker exceeds 240 VAC or the AVR firmware is incorrect.

Potential Root Cause(s): 

Voltage between Terminal 30 (R) and the L1 contact on the circuit breaker is below 240 VAC.

Potential Root Cause(s): 

Firmware update is required (review service bulletins), speed sensor wiring is touching ground, or a loss of fuel supply is present.

Potential Root Cause(s): 

Generator units are rated at 50% load imbalance between phases. Imbalances between phases can be measured with an ammeter. Correct or move the breaker load(s) as necessary.

Potential Root Cause(s): 

Frequency is less than 60 Hz at the line side of the circuit breaker and/or the controller.

Potential Root Cause(s): 

Engine speed is less than 3,400 RPM at the controller.

Potential Root Cause(s): 

Voltage between Terminal 29 (Y) and the L2 contact on the circuit breaker exceeds 240 VAC or the AVR firmware is incorrect.

Potential Root Cause(s): 

Voltage between Terminal 29 (Y) and the L2 contact on the circuit breaker is below 240 VAC.

Follow these instructions to access the event log from the controller:

1. Press Stop/Config to enter Manual Mode
2. Press and hold Stop/Config to begin accessing the Configuration settings
3. Press Stop/Config to access Configuration in Read Mode
4. Press and hold the up and down arrows simultaneously

1. Check that the engine has been filled to the correct level with the recommended oil. Is the oil at the correct level?
   • Yes - Go to Confirm Battery, Circuit Breaker, 15A Fuse, and Controller.
   • No - Slowly add oil until the correct oil level is reached. DO NOT OVERFILL.

1. The positive battery cable (red) must be connected to the positive battery (+) post and the negative battery cable (black) must be connected to the negative battery (-) post. Is the battery correctly connected?
   • Yes - Go to Check Circuit Breaker.
   • No - Correctly connect the battery.

1. Is the generator circuit breaker set to the ON (Closed) position?
   • Yes - Go to Check Fuse and GC-1030 Series Controller.
   • No - Set the generator circuit breaker to the ON (Closed) position.

1. Is the 15 amp ATO type fuse installed in the controller?
   • Yes - Go to step 2.
   • No - Install the 15 amp ATO type fuse in the controller.
2. Is the generator controller set to AUTO?
   • Yes - Go to Check Fuel Delivery.
   • No - Press AUTO/MANUAL on the controller. An LED illuminates to indicate that the system is in AUTO mode. Is a fault present on the controller?
     • No - Go to Confirm Fuel Delivery Settings (Type), and Supply Pressure.
     • Yes - Go to Using Linear Diagnostics for the corresponding fault displayed on the controller.

1. Is sufficient fuel available in the fuel supply tank?

   NOTICE - Fuel is only present on units with a liquid propane (LP) supply tank.

   • Yes - Go to step 2.
   • No - Replenish the fuel supply.
2. Are the main fuel supply valve and any in-line fuel shutoff valves open?
   • Yes - Go to Check Fuel Pressure.
   • No - Open the main fuel supply valve and any in-line fuel shutoff valves.

1. Remove the roof and front panel.
2. For 13 kW units only: press the fuel selector toggle switch (A, Figure 3) that is located on the top of the field connection box to the correct position -- LP or NG (B).

   
   Figure 3

3. Locate the main jet (A, Figure 4) and idle jet (B) on the engine. The number of turns counter-clockwise of each jet from a fully-seated position (0 turns) indicates whether the unit is configured to run on NG or LP. The jet settings for NG and LP are as follows:

    

   12-13kW NG and LP Configurations
   Model	Engine	Frequency	Fuel Type	Main Jet Turns	Idle Jet Turns
   12kW	BSPP 38 v/s	60 Hz	NG	1/2	2-1/2
   			LP	0	1/4
   13kW	BSPP 38 v/s	60 Hz	NG	1-3/8	3/8
   			LP	1/8	3/4

    

   
   Figure 4

4. The engine of your generator system is factory-calibrated and set to operate on NG. To convert to either fuel, do the steps that follow:
   • Locate the controller.
   • Press STOP/CONFIG to navigate to Manual Mode.
   • Press and hold the STOP/CONFIG button to access the configuration menu.
   • Press START/SELECT to enter Write Mode to edit the items in the configuration menu.

     NOTICE - If you are changing the setup in the generator's controller from the factory setting of NG fuel to LP fuel you will need to enter the configuration menu by using the Dealer Password, which is available on the Power Portal.

   • Navigate to the “SELECT PROFILE” page, press START/SELECT 3 times to access the profile selection row for the generator, and press START/SELECT once you have set the correct profile. For example “13KW_LP” for operating a 13kW unit running on LP fuel.

     NOTICE - Selecting a profile that is not intended for the generator can cause the generator to run erratically and can result in damage.

     <
   • To save the new fuel setting, press and hold the STOP/CONFIG button until “Saving Settings…” is displayed.
   • For 13 kW Units: DO NOT change the fuel regulator setting. Whether you are using NG or LP fuel this setting MUST be left at the factory setting of NG (A, Figure 5).

     
     Figure 5

1. Open the roof and remove the air inlet side end cap.
2. Locate the fuel selector valve (A, Figure 7) on top of the fuel pressure regulator (B). To convert to either type of fuel, do the steps that follow:

   
   Figure 7

   • Set the fuel selector. For LP, rotate the lever on the fuel selector valve until LP is aligned with “OUT” on the fuel regulator. For NG, rotate the lever clockwise 90° so the handle position of the lever will be up and down and the “NG” letters will be on the left.
   • For 17, 20, and some 26 kW PowerProtect units, locate the fuel selector switch (A, Figure 8) and select either LP or NG. For 18, 22, and some 26 kW PowerProtect units, locate the fuel selector switch (A, Figure 9) and select either LP or NG.

     
     Figure 8
     
     
     Figure 9

   • Locate the controller.
   • Press STOP/CONFIG to navigate to Manual Mode.
   • Press and hold the STOP/CONFIG button to access the configuration menu.
   • Press START/SELECT to enter Write Mode to edit the items in the configuration menu.

     NOTICE - If you are changing the setup in the generator's controller from the factory setting of NG fuel to LP fuel you will need to enter the configuration menu by using the Dealer Password, which is available on the Power Portal.

   • To set up the generator’s controller for LP fuel, enter the configuration menu by using the dealer password, which is available on the Power Portal. Navigate to “select profile” and push “select” on the correct profile for the generator. For example, choose “20KW_LP” for operating a 20kW unit running on LP fuel.

     NOTICE - Selecting a profile that is not intended for the generator can cause the generator to run erratically and could result in damage.

   • To save the new fuel setting, push and hold the STOP/CONFIG button until “Saving Settings…” displays.

NOTICE - The generator inlet fuel pressure should be 11-14 inches WC (LP) or 3.5-7 inches WC (NG).

1. Close the main fuel supply valve to stop the flow of fuel to the generator.
2. Locate the installer-supplied fuel pressure test port closest to the generator (A, Figure 32).

   NOTICE - If a test port does not exist, see the appropriate installation manual for instructions on installing it. To proceed with troubleshooting in the absence of a test port, go to step 4 of Check Fuel Solenoid and Thermal Fuses to use the test port in the fuel pressure regulator (B, Figure 32). Although use of this port will indicate whether fuel is present, it will not indicate whether the incoming fuel has dropped in pressure.

3. Obtain an analog manometer (C, Figure 32). Remove the test port plug and install the manometer.
4. Open the main fuel supply valve to start the flow of fuel to the generator.
5. Inspect the manometer gauge. Is the generator inlet fuel pressure 11-14 inches WC (LP) or 3.5-7 inches WC (NG).
   • Yes - Go to Check Fuel Solenoid and Thermal Fuses.
   • No - Repair or replace fuel delivery system. Test again.

   NOTICE - No more than 0.5 inches WC drop should be seen between static and dynamic fuel pressure and the fuel reading should be stable.

   
   Figure 32

Gather information and see it for yourself

• Customer description may not match symptom
• Control Panel indication may not be exact - check controller history
• Multiple faults at once

NOTICE - Make sure the controller is powered on and the PMD is in the ON position.

1. If an alarm is present on the controller (status LED light is flashing), access the controller and record the displayed error message.
2. Make sure the controller firmware is updated to the most recent version. To access the product information display and view the existing firmware version, press the down arrow twice on the controller.
3. Clear the alarm by pressing the up and down arrows simultaneously.
4. Refer to the GC-1030 Series Controller Alarms & Event Log for more details on the error messages, sections for correcting the alarm, and steps for accessing/ reviewing the Controller Event Log.

Tests include load testing the battery and confirming battery connections, verifying utility voltage input to the battery charger, and sufficient trickle charge (confirming battery charger is operational). Additional tests include confirming the starter relay signal and starter solenoid connection, and proper output at the Generator Controller and Relay Board components.

Review the “Generator Does Not Start” section for basic troubleshooting steps.

Tests include confirming fuel items, such as checking fuel supply pressure, fuel solenoid and thermal fuses, and fuel pressure regulator option. The engine may exhibit failure to turn over fast enough. Additional verification tests include engine items, such as checking spark, crankcase vacuum, and/or checking and adjusting valve clearance.

Review the “Generator Does Not Start” section for basic troubleshooting steps.

Tests include measuring generator voltage at the LOAD side of the circuit breaker, the control panel, and LINE side of the circuit breaker. Instructions for checking the winding resistance (Rotor, Stator, and Power Windings) and additional alternator tests, as well as performing an AVR Bypass Test (checking AC voltage and DC amperage) are also included in this section.

Review either the “Generator Starts and then Shuts Down” or “Generator Does Not Produce Voltage” sections for basic troubleshooting steps.

Tests include checking the frequency at the LINE side of the circuit breaker, and control panel, as well as checking the electronic governor.

Review either the “Generator Starts and then Shuts Down” or “Generator Does Not Produce Voltage” sections for basic troubleshooting steps.

Tests include checking for low engine oil pressure, and/or high engine temperature.

Review the “Generator Starts then Shuts Down” section for basic troubleshooting steps.

Run the engine and observe its performance. If the engine runs smoothly perform the check cylinder balance and crankcase vacuum tests. Additional troubleshooting instructions can be found in the appropriate Engine Service Manual for engines that perform poorly.

Review the “Generator Runs Rough” section for basic troubleshooting steps.

Technicians are provided with questions to check and confirm the state of the standby generator, organized by Battery, Fuel, Electrical Controls, Physical, Security, and Load Test.

Additional general information that technicians should note include Equipment (Generator and Transfer Switch), Owner, and Service information.

When diagnosing a standby generator issue, be sure to utilize all resources available to you, including the Troubleshooting Worksheet and/or Electrical Troubleshooting and Repair Manual. Once you have exhausted all options and resources internal to your company, Briggs & Stratton Technical Support is available to assist.

Technical Support Specialists will ask for the following unit information:

• Technician Name and DDM # (from your company)
• Standby Generator Model and Serial number
• Basic unit information such as 12V battery voltage, fuel type/ pressure, and Controller firmware settings
• Symptoms and the troubleshooting steps you have done so far

Throughout the year, especially during Hurricane/ Storm Season, wait times may increase. Technical Support provides a call back option where your spot in line is reserved, and an agent will call you back when they are available.

As of February 2025, new hold messages have been introduced assisting you with basic troubleshooting steps and product reminders.  Please let us know if they

For standby generators within their standard warranty period requiring major repair (e.g. engine, alternator, or (blank) replacement), a control authorization number may be required. Additional items requiring authorization may include, but are not limited to additional repair time, mileage, and/or site trip charge(s).

(indicate what was done; advise on outage simulation test, if necessary; thank them for trusting you and your business with maintaining/ servicing their standby generator)

1. Confirm the generator Controller is in AUTO mode, no fault codes are present, AND the generator circuit breaker is in the ON/ CLOSED state.
2. Close the lid of the generator.
3. Request approval from the customer, after discussing the “simulated outage event” details.
4. Remove the ATS outer panel to gain access to the Utility circuit breaker
5. Open, or turn OFF the Utility circuit breaker in the ATS. Power to the site/ home will be removed!
6. Confirm the engine start (ES) time delay: after 6 seconds, the generator should start.
7. Confirm normal-to-emergency (N-to-E) transfer time delay: after 20-50 seconds the ATS contactor will transfer from the Utility position, to the Generator position.
8. Verify generator power is being supplied to the site/ home.
9. Perform basic system checks at the Generator and ATS to verify system operation. Allow the generator to operate for a minimum of 5 minutes.
10. Return to ATS and close, or turn ON the Utility circuit breaker.
11. Confirm the emergency-to-normal (E-to-N) transfer time delay: after 10 seconds the system senses the utility power has returned, and the ATS contactor will transfer back to the Utility position (system must operate for a minimum 5 minutes before re-transferring).
12. Confirm the engine cool-down time delay: the engine enters a five minute cool-down period after re-transfer, and the generator returns to a standby state.
13. Confirm the generator Controller is in AUTO mode, no fault codes are present, AND the generator circuit breaker is in the ON/ CLOSED state.

(pull from Final Checks to remind Technicians what to record prior to leaving)

(items to clean-up)

Troubleshooting aid covering information utilized prior to and during conversations with Technical Support.

This manual provides a comprehensive linear path to correctly diagnose most generator problems, including those units with a GC-1030 Series Controller.

View Document”

Linear Logic Methodology

Before you start the diagnosis, answer the questions listed in the Introduction and Preliminary Checks sections before proceeding to the Using Linear Diagnostics section. This will determine the actual point at which to begin the diagnosis.

Parts Removal and Installation instructions

Illustrations and detailed instructions for removing and installing various standby generator components are included, organized in sections for the 12-13kW vertical and 17-26kW horizontal units.

040740
PowerProtect 13kW (PP13)
View Parts Manual

040746
PowerProtect 13kW (PPDX13)
View Parts Manual

040756
PowerProtect 18kW (PP18)
View Parts Manual

040786
PowerProtect 22kW (PP22)
View Parts Manual

040780
PowerProtect 22kW (PPDX22)
View Parts Manual

040806
PowerProtect 26kW (PP26)
View Parts Manual

040800
PowerProtect 26kW (PPDX26)
View Parts Manual

DSB1153
Any GC-1032 Controller service part that is manufactured AFTER January 01, 2024 will no longer have the firmware loaded. The data label located on the back of the GC-1032R controller will display the manufacturing date. Consult the documentation to upload the appropriate firmware version to the GC-1032 Controller, using the SmartFlash tool.
View Document

DSB1163
Air-cooled standby generators having R4.00, R4.01, or R4.02 firmware versions installed on the GC-1032 Controller may exhibit performance issues (e.g. exercise cycle does not execute properly). Consult the documentation to upload the appropriate firmware version to the GC-1032 Controller, using the SmartFlash tool.
View Document

Review the information listed for DSB1153 above.

Review the information listed for DSB1163 above.

DSB1160
Multiple firmware versions are available for the Smart AVR, resulting in specific compatibility conditions. Consult the documentation to verify that the correct AVR firmware version is installed after servicing/ replacing the generator’s Smart AVR.

View Document

Qualified service technicians must use the Firmware Programmer software to program the Smart AVR.

Firmware Programmer - Hardware/Software Requirements

• Smart AVR Assembly
• USB 2.0 standard B-type cable, also known as a USB Printer Cable
• Windows based PC or Laptop (NO tablets, smartphones, or Apple OS)
• Download the latest A1.3 or A1.4 Firmware firmware to your computer PRIOR to traveling onsite

NOTE: The same Firmware Programmer v1.1 software used for programming the Briggs & Stratton Standard Controller may also be used to program and verify programming on the Smart AVR.

View Document

Qualified service technicians must use the Smart Flash software to program the GC-1030 Series GENSET Controller.

Smart Flash - Hardware/Software Requirements

• GC1030 Series Controller
  • GC1032R running 3.18 or higher firmware
  • GC1032 running 2.10 or higher firmware
  • GC1031 running 8.00 or higher firmware
• USB 2.0 standard B-type cable, also known as a USB Printer Cable
• Windows based PC or Laptop (NO tablets, smartphones, or Apple OS)
• Stable internet connection, or download the latest firmware by using the “Download from Server” button PRIOR to traveling onsite

SmartFlash Software Security Code
To use the SmartFlash software, users will be prompted to enter a Security Code (1031). This will only be requested once, after installing/re-installing the software application.

Documentation
Instructions for programming the GC-1032R Controller can be found at the link below.
NOTE: Similar steps may be followed when programming a GC-1031 or GC-1032 Controller (selecting a specific generator from the software is not available).

View Document

• Digital Multimeter
• Analog Manometer
• Basic Hand Tools

• Briggs & Stratton Digital Tachometer and Hour Meter (Part No. 19598)
• Briggs & Stratton Ignition Tester (Part No. 19368)
• Briggs & Stratton Valve Adjustment Set (Part No. 19465) or equivalent set of 13mm offset box end wrench, T40 T-handle Torx wrench, and 5mm T-handle Allen wrench
• Briggs & Stratton Tang Adjusting Tool (Part No. 19480)
• Briggs & Stratton Jet Screwdriver Set (Part No. 19570)
• Briggs & Stratton Digital Volt/Ohm Meter with Amp Clamp (Part No. 19602)
• Feeler Gauge set (4-Blade Feeler Gauge Tool) or equivalent basic feeler gauge set (Part No. 19638)

Engine Parts

• 841359 - Air Cleaner
• 737434 - Spark Plug (2)
• 842921 - Oil Filter
• 806039S - Valve Cover Gasket (2)
• 807085 - Valve Cover Sealing Washer (4)
• 842622 - Cyl Head Gasket (2)
• 691613 - Exhaust Gasket (2)
• 844717 - Starter Motor
• 841281 - Oil Pressure Switch

Cold Weather Kit

• 6921 - Battery Warmer
• 6922 - Oil Warmer

Generator Parts

• 311316GS - Circuit Breaker
• 84007051 - Control Panel (GC-1030 Series Controller)
• 1985736GS - Control Panel Fuse
• 84010843 - Voltage Regulator (AVR)
• 772376 - Battery Charger
• 772336 - Relay Board
• 195130GS - Engine Temperature Switch
• 691656 - Starter Solenoid Relay
• 84006385 - Fuel Regulator
• 84011112 - Fuel Flex Hose
• 314290GS - Key Set

Engine Parts

• 841856 - Air Cleaner
• 792015 - Spark Plug (2)
• 842921 - Oil Filter
• 809732 - Valve Cover Gasket (2)
• 809730 - Cyl Head Gasket (2)
• 809872 - Exhaust Gasket (2)
• 84008634 - Starter Motor
• 84008635 - Starter Solenoid
• 841281 - Oil Pressure Switch

Cold Weather Kit

• 6840 - Oil Sump Warmer
• 6845 - Fuel Regulator Heater
• 6869 - Battery Warmer

Generator Parts

• 316187GS - Circuit Breaker (18kW)
• 311318GS - Circuit Breaker (22kW)
• 84007090 - Circuit Breaker (26kW)
• 84007051 - Control Panel (GC-1030 Series Controller)
• 1985736GS - Control Panel Fuse
• 84010843 - Voltage Regulator (AVR) for 18kW, 22kW (040780, 040781, 040786) and 26kW (040800, 040801, 040806)
• 772378 - Smart AVR for 26kW (040658, 040664, 040665, 040694)
• 772376 - Battery Charger
• 772336 - Relay Board
• 204426GS - Engine Temperature Switch
• 772333 - Starter Solenoid Relay
• 84006385 - Fuel Regulator
• 84011112 - Fuel Flex Hose
• 314290GS - Key Set

Boards

• 771701 - ACCM Board
• 770434 Circuit Board (TRCM)

Transfer Switch Contacts

• 314867GS - 100 Amp Contactor
• 315050GS - 150/200 Amp Contactor

Miscellaneous

• 192151GS - Fuse Holder
• 205110GS - Fuse
• 208106GS - Current Transformers

Using the Model Search feature on the PowerPortal, technicians can review product information, model specifications as well as access specific documentation including illustrated parts lists, operators & installation manuals, and warranty & repair manuals.

Access Model Search

eParts is a web based system for retrieving information about parts from Briggs & Stratton Energy Solutions. eParts lets you look up a standby generator and an engine model and display an Illustrated Parts List (IPL) of its assemblies.

You can:

• View the document attachments for the model
• View the IPL for each assembly
• Enter a part number to view which standby generator model it is associated with
• Additional purchasing benefits available from the main account login (DDM #)

Access eParts

Created for all Briggs & Stratton model engines and various product applications, The Power Channel provides technical video content and access to certifications, such as the VANGUARD Service Technician (VST) and Master Service Technician (MST) certifications.

Access the Power Channel

A primary account for the PowerPortal was created when you agreed to become an authorized partner with Briggs & Stratton. This is commonly referred to as a DDM account.

• Account information including open/closed invoices for your company, available from the Dealer Dashboard
• Product registration submissions and product service history
• Warranty claim submission & claim status check
• Sales & Marketing portal for ordering product brochures, specification sheets, and other literature and advertisement assets
• Create “technician accounts” for all staff members at your company

Access the Dealer Dashboard

Register a Technician

Something just as powerful on the PowerPortal is a Technician Account, which is created and managed under the primary account. These accounts are well suited for technicians or salespersons working at your company, needing access to the following items:

• Interactive web based parts look-up for all brands (illustrated parts lists)
• Robust technical support documentation including operators & installation manuals, service bulletins, and repair manuals
• Annual maintenance checklists for air-cooled and liquid-cooled standby generators

NOTE: Technician accounts are NOT able to place orders or file warranties, and ARE empowered to access the tools necessary to support your customers!