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Familiarization & Troubleshooting Guide

HAND-HELD GENERATOR
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BRIGGS & STRATTON CORPORATION Milwaukee, WI 53201 Part No. 190275-5/03 Printed in U.S.A.

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

Copyright 2003 Briggs & Stratton Corporation All rights reserved.

No part of this material may be reproduced or transmitted, in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without prior permission in writing from Briggs & Stratton Corporation.

Please click the Bookmarks tab at left to enable the search and navigational features of this document.

Electronic Version #190275 03/03

Hand-Held Series Generator

Familiarization & Troubleshooting Guide

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

Copyright 2003 Briggs & Stratton Corporation All rights reserved.

No part of this material may be reproduced or transmitted, in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without prior permission in writing from Briggs & Stratton Corporation.

Hand-Held Series Generators Familiarization & Troubleshooting Guide Tabe of Contents

TABLE OF CONTENTS

INTRODUCTION
4 4 5 8 9 10 10 11 11 11 12 12 12 12 12 12

TROUBLESHOOTING
22 23 23 23 24 24 26 27 27 28 28 29 29 30 Check (DC) Circuit Breaker Check Bridge Diode Check 12VDC Coil

In The Interest of Safety Safety Alert Symbols Safety Practices Generator Description Generator Components Serial Number Locations Generator Specifications Wiring Diagram Output Power (AC) Output Power (DC) Fuel System Components Fuel Group General Service Information Work Area Hand Tools Special Tools

Under-Voltage (DC)

1 2 3 4 5

Over-Voltage (AC) Check Capacitor Under-Voltage (AC) Check Receptacle Wiring Check (AC) Circuit Breaker Check Stator Power Winding Check Excitation Winding Check Rotor Winding Engine Switch Pilot Lamp

2
Case Separation

ASSEMBLY
33 34 35 36 37 37

DISASSEMBLY
Mounting The Rotor & Stator 15 15 17 18 Installing The Muffler Heat Shield Connecting The Wiring Harness Mount The Rear Case Half Mount The Fuel Tank Mount The Front Case Half

General Disassembly Considerations Access To Generator Components Rotor / Stator Removal

5
Resistance Values

APPENDIX
43 43 44

Torque Specifications Fasteners and Locations

Hand-Held Series Generators Familiarization & Troubleshooting Guide Table of Contents

1 2 3 4 5
2

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 1 Introduction

INTRODUCTION

Hand-Held Series Generators Familiarization & Troubleshooting Guide Introduction Section 1

INTRODUCTION

In the Interest of Safety

This manual outlines the construction, function and servicing procedures of the Briggs & Stratton Power Products Hand-Held generator series. It is structured for use by trained technicians that are working in a properly equipped shop. Familiarity with the proper method of using tools, measuring equipment and workshop procedures are essential to performing successful maintenance and repair on this equipment. Ensure that all specified tools and/or equipment are available before attempting to service this equipment. For a detailed discussion of the fundamental principles involved with the physics of electrical power generation, refer to the "Familiarization and Troubleshooting Guide (Publication #86262 Revision 3 or later)". This manual is available through your Briggs & Stratton Central Distributor. Safety Alert Symbols The safety alert symbol ( ) is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, CAUTION) is used with the alert symbol to indicate the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard. DANGER: Indicates a hazard which, if not avoided will result in death or serious injury. WARNING: Indicates a hazard which, if not avoided could result in death or serious injury.

CAUTION: Indicates a hazard which, if not avoided might result in death or serious injury.
CAUTION: When used without the alert symbol, indicates a situation that could result in damage to equipment.

DANGER
Generator produces powerful voltage. Failure to isolate generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy. When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility. Use a ground circuit fault interrupter (GFCI) in any damp or highly conductive area, such as metal decking or steel work. Do not touch bare wires or receptacles.

NOTE: This notation is used to inform you of a method, reference or procedure that could assist with specific operations or decisions.
HAZARD SYMBOLS AND MEANINGS

Toxic Fumes Electrocution

Explosion

Do not use generator with electrical cords which are worn, frayed, bare or otherwise damaged. Do not operate generator in the rain. Do not handle generator or electrical cords while standing in water, while barefoot, or while hands or feet are wet. Do not allow unqualified persons or children to operate or service generator.

Hot Surface Chemical Burns

Fire

Read

Explosive Pressure

Goggles

DANGER
Kick Back Disconnect Spark Plug Entanglement

Running generator gives off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide will cause nausea, fainting or death. Operate generator ONLY outdoors. Keep at least 2 feet of clearance on all sides of generator for adequate ventilation. Do not operate generator inside any building or enclosure, including the generator compartment of a recreational vehicle (RV).

DANGER
Failure to properly ground generator can result in electrocution, especially if the generator is equipped with a wheel kit. National electric code requires generator to be properly grounded to an approved earth ground. Call an electrician for local grounding requirements.

Hand-Held Series Generators Familiarization & Troubleshooting Guide Introduction Section 1

DANGER
Storage batteries give off explosive hydrogen gas during recharging. Hydrogen gas stays around battery for a long time after battery has been charged. Slightest spark will ignite hydrogen and cause explosion. You can be blinded or severely injured. Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery fluid will cause severe chemical burns. Do not allow any open flame, spark, heat, or lit cigarette around battery during, and for several minutes after charging. Wear protective goggles, rubber apron, and rubber gloves.

WARNING
Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. WHEN ADDING FUEL Turn generator OFF and let it cool at least 2 minutes before removing gas cap. Loosen cap slowly to relieve pressure in tank. Fill fuel tank outdoors. Do not overfill tank. Allow space for fuel expansion. Keep all fuel away from sparks, open flames, pilot lights, heat, and other ignition sources. Do not light a cigarette or smoke. WHEN OPERATING EQUIPMENT Do not tip engine or equipment at angle which causes fuel to spill. WHEN TRANSPORTING OR REPAIRING EQUIPMENT Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF. Disconnect spark plug wire. Do Not operate generator in a moving vehicle or watercraft, because motion can cause fuel to spill. WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK Store away from furnaces, stoves, water heaters, clothes dryer or other appliances that have pilot light or other ignition source because they can ignite fuel vapors.

Safety Practices
Generator exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Operate and service this equipment only in the open air where adequate ventilation is available. These generators were designed and manufactured for recreational applications. Do not attempt to modify the unit or use it for any application it was not designed for. If you have any questions about your generator's application, ask your dealer or consult the factory. The manufacturer could not possibly anticipate every circumstance that might involve a hazard. For that reason, warnings in manuals and warnings on tags or decals affixed to the units are not all-inclusive. If you intend to handle, operate or service a unit with a procedure or method not specifically recommended by the manufacturer, make sure that such a procedure or method will not render the equipment unsafe or pose a threat to you and others. Read these procedures carefully and become familiar with your generator set. Know its applications, its limitations and any hazards involved.

DANGER
Running engines produce heat. Temperature of muffler and nearby areas can reach or exceed 150F (65C). Severe burns can occur on contact. Do not touch hot surfaces. Allow equipment to cool before touching.

WARNING
This generator does not meet U.S. Coast Guard Regulation 33CFR-183 and should not be used on marine applications. Failure to use the appropriate U.S. Coast Guard approved generator could result in bodily injury and/or property damage.

WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Hand-Held Series Generators Familiarization & Troubleshooting Guide Introduction Section 1

Hand-held generators produce a very powerful voltage that can cause an extremely dangerous electrical shock. Avoid contact with bare wires, terminals, etc. Never permit an untrained person to service or assist with the procedures discussed in this guide. Never handle any kind of electrical cord or device while standing in water, while barefoot, or while hands or feet are wet. Do not use worn, bare, frayed or otherwise damaged electrical cord sets with any generator set. Using a defective cord may result in an electrical shock or damage to the test equipment and/or the unit. Gasoline is highly flammable and its vapors are EXPLOSIVE. Do not permit smoking, open flames, sparks or heat in the vicinity while handling gasoline. Avoid spilling gasoline on a hot engine. Comply with all laws regulating storage and handling of gasoline.
Do not overfill the fuel tank. Always allow room for fuel expansion. If the tanks are over-filled, fuel can overflow on `to a hot engine and cause FIRE or EXPLOSION. These units require an adequate flow of cooling air for their continued proper operation. Never operate or service any unit while inside any enclosure where the free flow of cooling air into and out of the unit might be obstructed. Without sufficient cooling airflow, the units quickly overheat, damaging the generator and/or nearby property. Never start or stop a unit with electrical loads connected to receptacles and with the connected loads turned ON. Start the engine and let it stabilize before connecting any electrical loads. Turn OFF and disconnect all electrical loads before shutting down any generator. This entire book is filled with important safety information - please read it carefully.

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 1 Introduction

Hand-Held Series Generators Familiarization & Troubleshooting Guide Introduction Section 1

GENERATOR DESCRIPTION

Figure 1 Internal Components

9 8

10

11

12

13

14 15

7 6 5 4 3 2 1 20
Item 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Nomenclature Vibration Mount Bearing Carrier Cooling Fan Rotor Bearing Rotor Bolt (M6-160) Rotor Assembly Stator Bolt (M6-90) Stator Assembly Fuel Tank Fuel Cap Item 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Nomenclature Fuel Inlet Filter Spark Plug Generator Case Half Fuel Filter Fuel Hose Fuel Valve Air Cleaner Carburetor Engine Engine Base

16 17 18

19

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 1 Introduction

GENERATOR COMPONENTS
Figure 2 External Components

Recoil Starter

Fuel Cap Engine Switch

1
Fuel Shut-Off

Choke Lever

Control Panel Oil Service Cover Grounding Lug Air Cleaner Data Plate Recoil Starter

Muffler

Spark Plug Access

Cooling Fan

Hand-Held Series Generators Familiarization & Troubleshooting Guide Introduction Section 1

Serial Number Locations

Figure 3 Engine Serial Number Location

Generator Specifications
Engine: Name: Type: GM82 or Vanguard Air Cooled, Four Cycle Gasoline Engine 80 cubic centimeters 1.8KW @ 4000RPM 1.3KW @ 3000RPM 0.4 Liter Recoil Starter

Displacement: Max. Power: Rated (AC) Power: Oil Capacity: Starting System: Oil Alert System: Yes

Generator: (AC) Frequency: 60Hz Phase: (AC) Rated Voltage: (AC) Rated Current::

N. American Single 120 VAC 7.5 Amps 900 VA 1000 VA 12 VDC @ 8.3 Amps Condenser 1.0 Continuous

Europe Single 230VAC 3.2 Amps 750 VA 900 VA 12VDC @ 8.3 Amps Condenser 1.0 Continuous

Figure 4 Generator Serial Number Location

(AC) Rated Output: (AC) Maximum Output: (DC) Output: Voltage Regulator: Rated Power Factor: Rated:

Other: Fuel Capacity: Continuous Operation: Noise Level: Dimensions: 4.5 Liter / 1.18 Gal 6.4 Hours 63 DBA @ 7 Meters Length: 465mm Width: 343mm Height: 371mm Dry Weight: 55 lbs. / 25 Kg 4.5 Liter / 1.18 Gal. 6.4 Hours 63 DBA @ 7 Meters 465mm 343mm 371mm 55lbs. / 25 Kg

10

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 1 Introduction

GENERATOR SYSTEMS
Figure 5 Generator Wiring Diagram

Output Power (AC)

The residual magnetism of the rotor induces an (AC) voltage in the power and excitation windings when the rotor is turned by hand (when recoil starter is pulled). The (AC) voltage of the excitation winding builds in the condenser until it discharges. This "capacitive discharge" then strengthens the magnetic field in the excitation winding. As the rotor windings "cut" this strengthened magnetic field, a higher (AC) voltage is induced in the rotor winding. The diode in the rotor rectifies the induced rotor (AC) to (DC). The intensified magnetic field of the rotor "cuts" across both the power and excitation windings. When the engine starts and spins the rotor, residual magnetism is overcome and this cycle continues to increase the (AC) output voltage of the 11

power and excitation windings until magnetic saturation and condenser capacity is balanced. This is the calculated "Rated Output" of the generator. When an external load is plugged into an output receptacle, the increased current flow intensifies the magnetic field of the power winding. As the magnetic field of the rotor "cuts" across the intensified field of the power winding, an additional voltage is induced into the rotor field winding. This increases the output of the power winding to compensate for the voltage drop of the load.

Output Power (DC)

(AC) voltages that are induced into the 12VAC winding are rectified to (DC) by a "full-wave" bridge rectifier.

Hand-Held Series Generators Familiarization & Troubleshooting Guide Introduction Section 1

Fuel System Components

Fuel Group: The components that make up the Fuel group include the items listed in Figure 6.
Figure 6 Fuel Systems Components
Shut-Off Valve Fuel Cap Assembly

GENERAL SERVICE INFORMATION Work Area

Good lighting and an elevated table will help you gain access to all of the mounting hardware and accessories of the handheld generator. Certainly, larger is better but a good minimum sized table would be 20in. by 30in. If casters are applied to the legs of the table, be sure they are secure and sturdy enough to support not only the generator but also the work being performed.

Fuel Hose

Tank Sump Filter Fuel Strainer Spill Well

Hand Tools
A minimum collection of standard mechanic's hand tools should include: 3/8" drive socket set (SAE) 3/8" drive socket set (Metric)

Mounting Brackets

A 3/8" drive ratchet

Tank

Short, medium and long 3/8" drive extensions A large (heavy) "soft" mallet A common screwdriver (medium length) A Phillips screwdriver (medium length) A Phillips screwdriver (short- "stubby") A large (heavy duty) screwdriver suitable for mild prying

The items listed in Figure 7 are part of the fuel cap and are not replaceable. If damage occurs to the fuel cap, its repair is limited to replacement.
Figure 7 Fuel Cap Assembly

Special Tools
Electronic Measuring Equipment: The measuring equipment used in troubleshooting should be of industrial quality and have the sensitivity to measure electronic values to the third decimal. Its accuracy should be within acceptable tolerances should have the ability to measure capacitance.

12

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 2 Disassembly

DISASSEMBLY

13

Hand-Held Series Generators Familiarization & Troubleshooting Guide Disassembly Section 2

14

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 2 Disassembly

General Disassembly Considerations

Always inspect the external condition of the plastic components before disassembling the unit. Look for cracks and broken plastic and be sure to note these conditions as existing before maintenance is undertaken. Hand-held generators are built to close tolerances. The fasteners used to hold the plastic shrouds and covers are special machine screws that have a "pilot" collar incorporated into the grip area of the screw (Figure 8).
Figure 8 Screws with Pilot Collar

NOTE: Do not attempt to remove the protective grill that surrounds the exhaust muffler. The fasteners that hold it in place are secured with plain nuts and lock-washers. If you attempt to remove the grill, it will be necessary to disassemble the case halves in order to reinstall it properly.

Case Separation
Remove the cover to the air cleaner. Set the air filter and support grill aside. Remove the two mounting nuts that hold the air filter assembly to the carburetor (Figure 48, Pg. 34). Remove the two screws that hold the handle of the unit together (Figure 9).
Figure 9 Remove Screws In Handle

Pilot Collars

NOTE: When assembling plastic components, be sure the "collar" of the screw fits into the opening of the shroud or cover. Pinching the plastic under the collar will break the plastic at the mounting locations.
The length of these fasteners is critical to the proper assembly of the unit. When disassembling the generator, it is recommended that the location and length of each fastener be noted. When troubleshooting becomes necessary, access to various components, systems and structural members is required. Regardless of the ultimate reason, a clear understanding of the unit's disassembly will save time and effort. At this point, position the unit so you are facing the muffler side of the generator. Remove only those fasteners that hold the rear case half. That is: Those screws around the lower base of the rear of the generator. The upper screws that secure the rear case-half on the right and left side of the generator. Grasp the rear case half and gently separate it from the generator unit.

15

Hand-Held Series Generators Familiarization & Troubleshooting Guide Disassembly Section 2

Remove the screw that is next to the fuel shut-off valve and retain the mounting bracket that supports the fuel tank (Figure 10).
Figure 10 Mounting Bracket Screw

2
Slide the fuel tank out of its cradle and remove the fuel supply hose from the bottom of the tank (Figure 11).
Figure 11 Remove Fuel Supply Hose

Hose to Tank

16

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 2 Disassembly

ACCESS TO GENERATOR COMPONENTS

Figure 12 Access To Generator Components

2
NOTE: At this point, you have visual access to many of the mechanical and electronic components of the generator (Figure 12).
Many individual electronic components are supported by clips and brackets that are molded parts of the front case half. This disassembly procedure assumes you are seeking access to the engine and generator for overhaul purposes and the components that are held by the case will be left in their mountings.
Figure 13 Generator Components

Position the unit so you are facing the front of the generator. Remove the screws around the base. Separate the electrical connectors at locations shown in Figures 13A and 13B. Set the front case-half aside.

Harness Connectors 17

Hand-Held Series Generators Familiarization & Troubleshooting Guide Disassembly Section 2

This provides sufficient access to the generator unit for troubleshooting, component replacement and overhaul (Figure 14).
Figure 14 Generator Unit Exposed

Rotor / Stator Removal

Step 1: For easier access, position the unit as shown in figure 16.
Figure 16 Position For Rotor Removal / Inspection

2
A view of the electrical components that are mounted on the inside of the front case-half is provided in Figure 15.
Figure 15 Electrical Components Mounted On Case

Step 2: Remove the cooling fan as shown. (Figure 17).

Figure 17 Remove Cooling Fan

NOTE: Mark the face of the fan to ensure proper reassembly.

18

Hand-Held Series Generators Familiarization & Troubleshooting Guide Disassembly Section 2

Step 3: Remove the heat shield mounting screws (Figure 18A). Step 4: Remove the rear bearing carrier mount bolts (Figure 18B).

Step 6: Remove the rear bearing carrier and the stator together (Figure 20).
Figure 20 Remove Stator Housing & Stator

Figure 18 Hardware (Heat Shield / Stator Housing)

Step 5: Remove the three through-bolts (Figure 19).

Figure 19 Remove Stator Through-Bolts

19

Hand-Held Series Generators Familiarization & Troubleshooting Guide Disassembly Section 2

20

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 3 Troubleshooting

TROUBLESHOOTING

21

Hand-Held Series Generators Familiarization & Troubleshooting Guide Troubleshooting Section 3

Figure 21 Under-Voltage (DC)

Troubleshooting Flow Chart

Test A
Check Engine RPM See Appendix OK?
NO

Repair/Replace See B&S #272147

DC OK?

YES

YES

NO

Test B
Check Receptacle Wiring

OK?

NO

Repair/Replace See Page 25

DC OK?

YES

YES

NO

Test C
Check DC Circuit Breaker

OK?

NO

Repair/Replace See Page 21

DC OK?

YES

END

YES

NO

Test D
Check Bridge Diode

OK?

NO

Repair/Replace See Page 21

DC OK?

YES

YES

NO

Test E
Check 12VDC Coil

OK?

NO

Repair/Replace See Page 21

DC OK?

YES

YES

NO

Test F
Check Rotor Winding

OK?

NO

Repair/Replace See Page 27

DC OK?

YES

YES

NO

Under Voltage (DC)

Refer to Figure 21 ("Under Voltage (DC)" Flow Chart) above for the sequential steps involved with this procedure. To separate the case halves, see page 13.

Test A: - Check Engine RPM (See Appendix) Test B: - Check Receptacle Wiring (Page 25) 22

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 3 Troubleshooting

Test C: - Check (DC) Circuit Breaker Step 1: Remove the three screws that secure the control panel to the face of the generator unit. Step 2: Remove both the terminals at the back of the circuit breaker (Figure 22A).

Figure 23 Checking The Bridge Diode

Positive Probe (+)

Negative Probe (-)

Step 3: With the circuit breaker ON and your VOM set to ohms, check for continuity at the terminals of the circuit breaker (Figure 22B).
Figure 22 Checking (DC) Circuit Breaker

(+) (+) ~1 ~2 (-) No No No

~1 Yes No No

~2 Yes No No

(-) Yes Yes Yes

Test E: - Check 12VDC Coil With the control panel still removed: Step 1: Locate and separate the harness connector that has the two brown wires coming.from the stator.

B - Continuity = Circuit Breaker OK - No Continuity = Defective Circuit Breaker.

Step 2: With your VOM set to ohms, read the coil resistance at the terminal of the brown leads in the connector (Figure 24).
Figure 24 Reading 12VDC Coil Resistance

Replace Circuit Breaker Test D: - Check Bridge Diode With the control panel still removed: Step 1: Locate and separate the harness connector that has the two brown wires. Push the male half of the connector aside.

Brown

NOTE: You must follow the Diode Test instructions that are provided with the meter you are using.
Step 2: Using the female terminals of the brown wires and the positive output terminal of the cigarette lighter, or the DC receptacle, you can check continuity of the bridge diode wiring (Figure 23).

Step 3: Compare readings with resistance values in the apppendix. Test F: - Check Rotor Winding (See Test G on Page 27) 23

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 3 Troubleshooting

Figure 25 Over-Voltage (AC)

Troubleshooting Flow Chart

Test A
Check Engine RPM See Appendix

OK?
NO

Test B
YES

Check Capacitor

OK?
YES

NO

Repair/Replace See Page 22

NO

Repair/Replace See B&S #272147

AC OK? YES

END

YES

AC OK? NO

"Over Voltage" (AC)

Refer to Figure 25 ("Over Voltage (AC)" Flow Chart) above for the sequential steps involved with this procedure. To separate the case halves, see page 13. Test A: - Check Engine RPM (See Appendix) Test B: - Check Capacitor The capacitor can be checked without disassembling the unit case-halves. Step 1: Remove the three screws that secure the control panel to the face of the generator unit (Figure 26).

Figure 26 Remove Control Panel

Step 2: Disconnect the harness connector that has the two yellow wires. Step 3: Using a jumper wire, (Figure 27) short the two yellow terminals that come from the capacitor. Then remove the jumper wire.

24

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 3 Troubleshooting

Figure 27 Short the Capacitor Terminals

Yellow

Step 4: Refer to the owner's manual of your VOM and test the capacitor according to the directions for your equipment.
Figure 28 Testing the Capcitor

Find the rating of the capacitor on its body or in the appendix of this manual. Compare reading with the stated value . Replace the capacitor if it is found to be faulty.

25

Hand-Held Series Generators Familiarization & Troubleshooting Guide Troubleshooting Section 3

Figure 29 Under-Voltage (AC)

Troubleshooting Flow Chart

Test A
Check Engine RPM See Appendix

OK?

NO

Repair/Replace See B&S #272147

AC OK?

YES

YES

NO

Test B
Check Receptacle Wiring

OK?

NO

Repair/Replace See Page 25

AC OK?

YES

YES

NO

Test C
Check AC Circuit Breaker

OK?

NO

Repair/Replace See Page 25

AC OK?

YES

END

YES

NO

Test D
Check Stator Power Winding

OK?

NO

Repair/Replace See Page 26

AC OK?

YES

YES

NO

Test E
Check Capacitor

OK?

NO

Repair/Replace See Page 22

AC OK?

YES

YES

NO

Test F
Check Excitation Winding

OK?

NO

Repair/Replace See Page 26

AC OK?

YES

YES

NO

Test G
Check Rotor Winding

OK?

NO

Repair/Replace See Page 27

AC OK?

YES

YES

NO

26

Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 3 Troubleshooting

Under Voltage (AC)

Refer to Figure 29 ("Under Voltage (AC)" Flow Chart) on the preceding page for the sequential steps involved with this procedure. To separate the case halves, see page 13. Test A: - Check Engine RPM (See Appendix) Test B: - Check Receptacle Wiring Step 1: Remove the three screws that secure the control panel to the face of the generator unit. Step 2: Test the receptacle for: - Shorted contacts. - Burned or cracked insulation material. - Faulty terminal screws (Figure 30).
Figure 30 AC Receptacle

Test C: - Check AC Circuit Breaker

Step 1: Remove both the terminals at the back of the circuit breaker (Figure 31A). Step 2: With the circuit breaker CLOSED and your VOM set to ohms, check for continuity at the terminals of the circuit breaker (Figure 31B).
Figure 31 Checking Circuit Breaker

3
- Continuity: = Circuit Breaker - OK - No Continuity: = Defective Circuit Breaker. Replace Circuit Breaker

Step 3: If any faults are found, - Replace receptacle.

27

Hand-Held Series Generators Familiarization & Troubleshooting Guide Troubleshooting Section 3

Test D: - Check Stator Power Winding Step 1: Disconnect the 4-pin harness connector that contains the yellow wires. Step 2: On the male portion of the connector, locate the pins that connect the blue and red wires (This harness should be coming from the generator stator assembly see figure 32). Step 3: With your VOM set to ohms, measure the resistance across the blue and red wires that come from the stator (Figure 32).

Test F: - Check Excitation Winding Step 1: Disconnect the harness connector that contains the yellow wires. Step 2: On the male portion of the connector, find the pins that connect the two yellow wires (This harness should be coming from the generator stator assembly see figure 33). Step 3: With your VOM set to ohms, measure the resistance across the two yellow wires that come from the stator (Figure 33).
Figure 33 Checking Excitation Winding

Figure 32 Checking Stator Power Winding

Compare reading with the resistance values in the appendix. - Within tolerance: Power winding is good - Exceeds tolerance: Replace Stator Test E: - Check Capacitor (Page 22)

Compare reading with the resistance values in the appendix. - Within tolerance: Excitation winding is good - Exceeds tolerance: Replace Stator

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 3 Troubleshooting

Test G: - Check Rotor Winding The rotor is considered a non-serviceable part because it is a sealed unit that would require disassembly to properly test. Therefore, it is by process of eliminating all other possible faults that the rotor can be considered faulty.

Engine Switch
Step 1: Remove the three screws that secure the control panel to the face of the generator unit. Step 2: Remove the terminals from the switch. Step 3: With your VOM set to ohms, cycle the switch to ON and test for continuity (Figure 34).
Figure 34 Checking The Engine Switch

NOTE: Piercing the red or blue wire and checking across the terminal post of the rotor diode is not recommended.
Before rotor replacement, follow the checklist outlined below: Check Engine RPM Check Capacitor Check Output Receptacle & Wiring Check Circuit Breaker (AC) Check Circuit Breaker (DC) Check Stator Power Winding Check Excitation Winding Check Bridge Diode Check 12VDC Coil

3
- You should have continuity. Step 4: Cycle the switch to OFF. - You should not have continuity.

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Troubleshooting Section 3

Pilot Lamp
Some early units were equipped with a green pilot lamp. If this is the case, troubleshoot the lamp using the instructions that follow; Step 1: Remove the three screws that secure the control panel to the face of the generator unit. Step 2: Remove the terminals from the lamp. Step 3: With your VOM set to ohms, check for continuity through the lamp (Figure 35).
Figure 35 Checking The Pilot Lamp

3
- No continuity: Replace lamp.

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 4 Assembly

ASSEMBLY

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 4 Assembly

Mounting The Rotor & Stator

Position the generator/base plate assembly as shown in figure 36, before mounting the stator assembly.
Figure 36 Generator / Base Plate Assembly

Position the stator and the rear bearing carrier over the rotor and align the feet with the mounting holes in the base plate (Figure 38).
Figure 38 Positioning The Stator

Mount the rotor on the tapered shaft of the engine (Figure 37).
Figure 37 Mount The Rotor

Install the bolts but do not tighten yet. Make sure the stator is seated in the machined lands of its cradle as shown in figure 39A and 39B.
Figure 39 Seating The Statot Assembly

With the stator properly seated in the machined lands of its cradle:

NOTE: The rotor is not timed in any way.

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Assembly Section 4

Install the three stator through-bolts and tighten until the rear bearing carrier is secure (Figure 40).
Figure 40 Securing The Stator Assembly

Before tightening the rotor mount bolt: Check the orientation of the fan (Figure 42).
Figure 42 Cooling Fan Orientation

Check to make sure there are no obstructions to the rotation of the rotor assembly. Torque the through bolts to 85 lbs. in. Torque the mounting bolts in the feet of the rear bearing carrier to 180 lbs. in. Slip the rotor mount bolt through the cooling fan. Start the bolt in the threads of the engine output shaft by hand (Figure 41). Torque the rotor mount bolt to 100 lbs. in.

Install The Muffler Heat Shield

Slip the heat shield between the muffler and the generator until the mounting flanges of the rear bearing carrier align with the mounting flange of the heat shield (Figure 43A & 43B).

Figure 41 Installing Rotor Mount Bolt Figure 43 Generator Heat Shield

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 4 Assembly

Install the mounting screws and tighten until the heat shield is secure.

Figure 45 Harness Connectors

NOTE: Make sure that the bent angles of the heat shield are in contact with surfaces of the engine as shown in figure 44.
Figure 44 Check Heat Shield Contact And Mounting

Connect one lead of the engine run switch to the engine ground wire. Connect the other wire from the engine run switch to the connector that also houses the blue wire from the ignition coil (Figure 46). Check to make sure that all the mounting hardware is tight and secure.
Figure 46 Ground And Run Switch

Connecting The Wiring Harness

The control panel that is mounted in the front case half is connected to the generator by means of two four-pin cable connectors. The associated wires colors are identical. Match the wire colors of the two harness connectors and seat each connector until it locks into place (Figure 45).

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Assembly Section 4

Mount The Rear Case Halve

Position the unit as shown in figure 47.
Figure 47 Unit Positioned For Closure

Align the rear case half with the mounting holes in the generator carriage. Refer to figure 49A & B and place the fasteners as shown.
Figure 49 Rear Case Half Fasteners

M6-16

Mount the air cleaner housing to the two studs that extend through the carburetor (Figure 48A). Insert the oil breather hose into the back of the air cleaner housing (Figure 48B).
Figure 48 Breather Tube & Air Filter Housing

M6-20

M6-20

The tank support brackets are shown in figure 50A & B. Insert the left-hand tank support bracket inside the case stiffener and secure to the rear case half with a M5-16 screw with a medium pilot collar (Figure 50A). Mount the right hand bracket as shown in figure 50B.

4
A B

Figure 50 Fuel Tank Support Brackets

M5-16

NOTE: Make sure that the steel bushings are installed in the housing for the air cleaner (Figure 48A).
The rear case half is mounted on the carriage first.

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 4 Assembly

Mount The Fuel Tank

Inspect the tank for the following items; Ensure that the fuel strainer is installed in the bottom of the tank sump. Check that the rubber vibration seals are glued on the seams of the fuel tank. Seat the tank in the area above the support brackets (Figure 51).
Figure 51 Mounting The Fuel Tank

Mount The Front Case Half

Before mounting the front case half, ensure that the LOS module is oriented on its mounting as shown in figure 53.
Figure 53 LOS Orientation

Position the front case half close enough to the generator unit in order to make the wiring connections to the Low Oil Sense (LOS) module and start switch (Figure 54).
Figure 54 Start Switch & (LOS) Wiring

Connect the fuel supply hose to the tank as shown in figure 52.
Figure 52 Connecting The Fuel Supply Hose

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Assembly Section 4

Route the starter rope through its opening in the case. Align the front case half with the mounting points in the generator carriage and install the fasteners (figure 55).
Figure 55 Fastener Locations On Front Case Half

Figure 57 Wiring Harness Connections

Install the control panel face plate (Figure 58).

Figure 58 Install Control Panel

With the mounting fasteners tight, connect the wiring harness connectors through the opening of the control panel (Figure 56).
Figure 56 Access To Wiring Harness

4
Install oil service cover (Figure 59). Match the colors of the wires.

NOTE: Match the color-coding of the wires to make sure that you are making the proper connections (Figure 57).
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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 4 Assembly

Figure 59 Install Oil Service Door

Figure 61 Install Spill Well & Fuel Cap

Install air filter assembly (Figure 60).

Figure 60 Install Air Filter Assembly

4
Install fuel spill well and fuel cap (Figure 61).

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 5 Appendix

APPENDIX
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Hand-Held Series Generators Familiarization & Troubleshooting Guide Appendix Section 5

5
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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 5 Appendix

APPENDIX Resistance Values

Rotors:
(60HZ) (50HZ) 4.06 ohm 4.10 ohm Connecting Rod Crankcase Cover Muffler Head Bolt Flywheel Nut Spark Plug Oil Drain Plug (50HZ) Excitation Winding Power Winding 12VDC Winding 4.79 ohm 4.33 ohm .510 ohm Cooling Fan Pivot Bolt General Screws Rocker Arm Assy. CT Bolt M6x30 M6x12 M8 M8 M8x55 M12 M14 M10 5/16" M8 M5 M6x16 M8 M6 M8 Rocker Box Cover 14 Fu 14 Fu M6x12

Torque Specifications
Engine:
Item Size Torque Value (In. Lbs.) 85 85 180 180 220 400 180 180 85 180 35 45 180 85 180 45

Stators:
(60HZ) Excitation Winding Power Winding 12VDC Winding 3.911 ohm 1.010 ohm .429 ohm

Capacitors:
(60HZ) (50HZ)

Generator:
Rotor Bolt Stator Bolt Tapping Screw General Screws M6 M6 M6 M4 M5 M6 M8 100 85 45 20 35 45 180

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Appendix Section 5

Figure 62 Fastener Sizes and Locations

M5-10 M5-10 M5-16

M6-20

M6-16

M5-16 M6-16

M6-16

M6-16

M6-20

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Hand-Held Series Generators Familiarization & Troubleshooting Guide Section 5 Appendix

Figure 63 Fastener Sizes and Locations (Continued)

M6-90

M6-160 M8-12

M8-12

M8

Self-Tapping Screw

M8-12

5
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5
46