190275gs hand held generators

BRIGGS & STRATTON CORPORATIONMilwaukee, WI 53201

Part No. 190275-5/03 Printed in U.S.A.

Look for these other repair manuals from theBriggs & Stratton Power Products line:

B3277GS Pressure Washer Familiarization& Troubleshooting Guide

86262 Generator Familiarization & Troubleshooting Guide

275110 Outboard Motor Repair Manual

Quality Starts With AMaster Service Technician

®

TM

Visit us at:www.briggsandstratton.comwww.generac-portables.comwww.briggspowerproducts.com

Familiarization & Troubleshooting Guide

HAND-HELD GENERATOR

For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

FOREWORD

This guide has been written and published by Briggs & Stratton Corporation to aid our dealers’ mechanics andcompany 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 similarproducts, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in therecommended servicing procedures for these products, which includes the use of mechanics’ hand tools and anyspecial 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 ofperforming such operations.

We could not possibly know of and advise the service trade of all conceivable procedures or methods by which aservice might be performed, nor of any possible hazards and/or results of each procedure or method.We have notundertaken any such wide evaluation.Therefore, anyone who uses a procedure or method not described by themanufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be endangered bythe service or operating procedure selected.

All information, illustrations, and specifications contained in this guide are based on the latest productioninformation available at the time of publication. However, Briggs & Stratton Corporation reserves the right tochange, 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 ormechanical, including photocopying, recording or by any information storage and retrieval system, without priorpermission in writing from Briggs & Stratton Corporation.

Hand-Held Series GeneratorFamiliarization & Troubleshooting Guide

Ele

ctro

nic

Ver

sio

n #

1902

75 0

3/03

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

®

FORWARD

This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics andcompany 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 similarproducts, manufactured by Briggs & Stratton Power Products Group®. It is also assumed that they have beentrained in the recommended servicing procedures for these products, which includes the use of mechanics handtools 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 ofperforming such operations.

We could not possibly know of and advise the service trade of all conceivable procedures or methods by which aservice might be performed, nor of any possible hazards and/or results of each procedure or method. We havenot undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described bythe manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will beendangered by the service or operating procedure selected.

All information, illustrations, and specifications contained in this guide are based on the latest productioninformation available at the time of publication. However, Briggs & Stratton Corporation reserves the right tochange, 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 ormechanical, including photocopying, recording or by any information storage and retrieval system, without priorpermission in writing from Briggs & Stratton Corporation.

1

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

TABLE OF CONTENTS

Tabe of Contents

1

2

3

4

5

INTRODUCTION1

DISASSEMBLY2ASSEMBLY4

APPENDIX5

TROUBLESHOOTING3

In The Interest of Safety 4

Safety Alert Symbols 4

Safety Practices 5

Generator Description 8

Generator Components 9

Serial Number Locations 10

Generator Specifications 10

Wiring Diagram 11

Output Power (AC) 11

Output Power (DC) 11

Fuel System Components 12

Fuel Group 12

General Service Information 12

Work Area 12

Hand Tools 12

Special Tools 12

Under-Voltage (DC) 22

Check (DC) Circuit Breaker 23

Check Bridge Diode 23

Check 12VDC Coil 23

Over-Voltage (AC) 24

Check Capacitor 24

Under-Voltage (AC) 26

Check Receptacle Wiring 27

Check (AC) Circuit Breaker 27

Check Stator Power Winding 28

Check Excitation Winding 28

Check Rotor Winding 29

Engine Switch 29

Pilot Lamp 30

Mounting The Rotor & Stator 33

Installing The Muffler Heat Shield 34

Connecting The Wiring Harness 35

Mount The Rear Case Half 36

Mount The Fuel Tank 37

Mount The Front Case Half 37

Resistance Values 43

Torque Specifications 43

Fasteners and Locations 44

General Disassembly Considerations 15

Case Separation 15

Access To Generator Components 17

Rotor / Stator Removal 18


2

Table of Contents

1

2

3

4

5

3

Section 1 • Introduction


INTRODUCTION 1

INTRODUCTION

4

Introduction • Section 1


1In the Interest of SafetyThis manual outlines the construction,function and servicing procedures ofthe Briggs & Stratton Power Products®“Hand-Held” generator series. It isstructured for use by trainedtechnicians that are working in aproperly equipped shop. Familiaritywith the proper method of using tools,measuring equipment and workshopprocedures are essential to performingsuccessful maintenance and repair onthis equipment.

Ensure that all specified tools and/orequipment are available beforeattempting to service this equipment.

For a detailed discussion of thefundamental principles involved withthe physics of electrical powergeneration, refer to the "Familiarizationand Troubleshooting Guide(Publication #86262 Revision 3 orlater)". This manual is availablethrough your Briggs & Stratton CentralDistributor.

Safety Alert Symbols

NOTE: This notation is used toinform you of a method, referenceor procedure that could assist withspecific operations or decisions.

HAZARD SYMBOLS AND MEANINGS

Toxic Fumes Electrocution

Hot Surface Chemical Burns

Explosive Pressure

Kick Back EntanglementDisconnectSpark Plug

Fire

Read Goggles

Explosion

• Operate generator ONLY outdoors.

• Keep at least 2 feet of clearance on allsides of generator for adequateventilation.

• Do not operate generator inside anybuilding or enclosure, including thegenerator compartment of arecreational vehicle (RV).

Running generator gives offcarbon monoxide, anodorless, colorless, poisongas.

Breathing carbon monoxidewill cause nausea, fainting ordeath.

The safety alert symbol ( ) is usedto identify safety information abouthazards that can result in personalinjury. A signal word (DANGER,WARNING, CAUTION) is usedwith the alert symbol to indicate thepotential severity of injury. In addition,a hazard symbol may be used torepresent the type of hazard.

DANGER: Indicates a hazardwhich, if not avoided will resultin death or serious injury.

WARNING: Indicates a hazardwhich, if not avoided couldresult in death or seriousinjury.

CAUTION: Indicates a hazardwhich, if not avoided mightresult in death or seriousinjury.

CAUTION: When used without thealert symbol, indicates a situation thatcould result in damage to equipment.

DANGER

• When using generator for backuppower, notify utility company. Useapproved transfer equipment to isolategenerator from electric utility.

• Use a ground circuit fault interrupter(GFCI) in any damp or highlyconductive area, such as metal deckingor steel work.

• Do not touch bare wires orreceptacles.

• Do not use generator with electricalcords which are worn, frayed, bare orotherwise damaged.

• Do not operate generator in the rain.

• Do not handle generator or electricalcords while standing in water, whilebarefoot, or while hands or feet arewet.

• Do not allow unqualified persons orchildren to operate or servicegenerator.

Generator producespowerful voltage.

Failure to isolate generatorfrom power utility can resultin death or injury to electricutility workers due tobackfeed of electrical energy.

DANGER

• National electric code requiresgenerator to be properly grounded toan approved earth ground. Call anelectrician for local groundingrequirements.

Failure to properly groundgenerator can result inelectrocution, especially if thegenerator is equipped with awheel kit.

DANGER

5



Safety Practices

• Generator exhaust gases containDEADLY carbon monoxide gas.This dangerous gas, if breathedin sufficient concentrations, cancause unconsciousness or evendeath. Operate and service thisequipment only in the open airwhere adequate ventilation isavailable.

• These generators were designedand manufactured forrecreational applications. Do notattempt to modify the unit oruse it for any application it wasnot designed for. If you have anyquestions about your generator'sapplication, ask your dealer orconsult the factory.

• The manufacturer could notpossibly anticipate everycircumstance that might involve ahazard. For that reason, warningsin manuals and warnings on tagsor decals affixed to the units arenot all-inclusive. If you intend tohandle, operate or service a unitwith a procedure or method notspecifically recommended by themanufacturer, make sure thatsuch a procedure or method willnot render the equipment unsafeor pose a threat to you andothers.

• Read these procedures carefullyand become familiar with yourgenerator set. Know itsapplications, its limitations andany hazards involved.

• Do not allow any open flame, spark,heat, or lit cigarette around batteryduring, and for several minutes aftercharging.

• Wear protective goggles, rubberapron, and rubber gloves.

Storage batteries give offexplosive hydrogen gasduring recharging.

Hydrogen gas stays aroundbattery for a long time afterbattery has been charged.

Slightest spark will ignitehydrogen and causeexplosion.

You can be blinded orseverely injured.

Battery electrolyte fluidcontains acid and isextremely caustic.

Contact with battery fluidwill cause severe chemicalburns.

DANGER

• Do not touch hot surfaces.

• Allow equipment to cool beforetouching.

Running engines produceheat. Temperature of mufflerand nearby areas can reachor exceed 150°F (65°C).

Severe burns can occur oncontact.

DANGER

• This generator does not meet U.S.Coast Guard Regulation 33CFR-183 andshould not be used on marineapplications.

• Failure to use the appropriate U.S.Coast Guard approved generator couldresult in bodily injury and/or propertydamage.

WARNING

WHEN ADDING FUEL

• Turn generator OFF and let it cool atleast 2 minutes before removing gascap. Loosen cap slowly to relievepressure in tank.

• Fill fuel tank outdoors.

• Do not overfill tank. Allow space forfuel expansion.

• Keep all fuel away from sparks, openflames, pilot lights, heat, and otherignition sources.

• Do not light a cigarette or smoke.

WHEN OPERATING EQUIPMENT

• Do not tip engine or equipment atangle which causes fuel to spill.

WHEN TRANSPORTING ORREPAIRING EQUIPMENT

• Transport/repair with fuel tank EMPTYor with fuel shutoff valve OFF.

• Disconnect spark plug wire.

• Do Not operate generator in a movingvehicle or watercraft, because motioncan cause fuel to spill.

WHEN STORING FUEL OREQUIPMENT WITH FUEL INTANK

• Store away from furnaces, stoves,water heaters, clothes dryer or otherappliances that have pilot light or otherignition source because they can ignitefuel vapors.

Fuel and its vapors areextremely flammable andexplosive.

Fire or explosion can causesevere burns or death.

WARNING

The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects,or other reproductive harm.

WARNING

6

• Hand-held generators produce a very powerfulvoltage that can cause an extremely dangerouselectrical shock. Avoid contact with bare wires,terminals, etc. Never permit an untrained person toservice or assist with the procedures discussed in thisguide.

• Never handle any kind of electrical cord or devicewhile standing in water, while barefoot, or whilehands or feet are wet.

• Do not use worn, bare, frayed or otherwise damagedelectrical cord sets with any generator set. Using adefective cord may result in an electrical shock ordamage to the test equipment and/or the unit.

• Gasoline is highly flammable and its vapors areEXPLOSIVE. Do not permit smoking, open flames,sparks or heat in the vicinity while handling gasoline.Avoid spilling gasoline on a hot engine. Comply withall laws regulating storage and handling of gasoline.

• Do not overfill the fuel tank. Always allow room for fuelexpansion. 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 theircontinued proper operation. Never operate or service anyunit while inside any enclosure where the free flow ofcooling air into and out of the unit might be obstructed.Without sufficient cooling airflow, the units quicklyoverheat, damaging the generator and/or nearby property.

• Never start or stop a unit with electrical loads connectedto receptacles and with the connected loads turned ON.Start the engine and let it stabilize before connecting anyelectrical loads. Turn OFF and disconnect all electricalloads before shutting down any generator.

• This entire book is filled with important safety information - please read it carefully.



7



1

8

Item Nomenclature

1. Vibration Mount

2. Bearing Carrier

3. Cooling Fan

4. Rotor Bearing

5. Rotor Bolt (M6-160)

6. Rotor Assembly

7. Stator Bolt (M6-90)

8. Stator Assembly

9. Fuel Tank

10. Fuel Cap

Item Nomenclature

11. Fuel Inlet Filter

12. Spark Plug

13. Generator Case Half

14. Fuel Filter

15. Fuel Hose

16. Fuel Valve

17. Air Cleaner

18. Carburetor

19. Engine

20. Engine Base

GENERATOR DESCRIPTION



Figure 1 — Internal Components

1

7

12 13

14

15

16

17

18

19

20

11109

8

6

5

4

3

2

1

9

GENERATOR COMPONENTS



Figure 2 — External Components

Control Panel

Oil Service Cover

Grounding Lug

Muffler

Spark Plug Access

Recoil Starter

Recoil Starter

Engine Switch

Air Cleaner

Data Plate

Cooling Fan

Choke Lever

Fuel Shut-Off

Fuel Cap 1

10

Serial Number Locations Generator Specifications

Engine:

Name: GM82 or Vanguard

Type: Air Cooled, Four Cycle Gasoline Engine

Displacement: 80 cubic centimeters

Max. Power: 1.8KW @ 4000RPM

Rated (AC) Power: 1.3KW @ 3000RPM

Oil Capacity: 0.4 Liter

Starting System: Recoil Starter

Oil Alert System: Yes

Generator: N. American Europe

(AC) Frequency: 60Hz

Phase: Single Single

(AC) Rated Voltage: 120 VAC 230VAC

(AC) Rated Current:: 7.5 Amps 3.2 Amps

(AC) Rated Output: 900 VA 750 VA

(AC) Maximum Output: 1000 VA 900 VA

(DC) Output: 12 VDC 12VDC

@ 8.3 Amps @ 8.3 Amps

Voltage Regulator: Condenser Condenser

Rated Power Factor: 1.0 1.0

Rated: Continuous Continuous

Other:

Fuel Capacity: 4.5 Liter / 1.18 Gal 4.5 Liter / 1.18 Gal.

Continuous Operation: 6.4 Hours 6.4 Hours

Noise Level: 63 DBA 63 DBA

@ 7 Meters @ 7 Meters

Dimensions: Length: 465mm 465mm

Width: 343mm 343mm

Height: 371mm 371mm

Dry Weight: 55 lbs. / 25 Kg 55lbs. / 25 Kg



Figure 3 — Engine Serial Number Location

Figure 4 — Generator Serial Number Location

1

11

Output Power (AC)The residual magnetism of the rotor induces an (AC)voltage in the power and excitation windings when the rotoris turned by hand (when recoil starter is pulled). The (AC)voltage of the excitation winding builds in the condenseruntil it discharges. This "capacitive discharge" thenstrengthens the magnetic field in the excitation winding. Asthe rotor windings "cut" this strengthened magnetic field, ahigher (AC) voltage is induced in the rotor winding. Thediode in the rotor rectifies the induced rotor (AC) to (DC).The intensified magnetic field of the rotor "cuts" across boththe power and excitation windings. When the engine startsand spins the rotor, residual magnetism is overcome and thiscycle continues to increase the (AC) output voltage of the

power and excitation windings until magnetic saturation andcondenser capacity is balanced. This is the calculated "RatedOutput" of the generator.

When an external load is plugged into an output receptacle,the increased current flow intensifies the magnetic field ofthe power winding. As the magnetic field of the rotor "cuts"across the intensified field of the power winding, anadditional voltage is induced into the rotor field winding.This increases the output of the power winding tocompensate for the voltage drop of the load.

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

GENERATOR SYSTEMS



Figure 5 — Generator Wiring Diagram

1

12

Fuel System ComponentsFuel Group:

The components that make up the Fuel group include theitems listed in Figure 6.

The items listed in Figure 7 are part of the fuel cap and arenot replaceable. If damage occurs to the fuel cap, its repair islimited to replacement.

GENERAL SERVICE INFORMATION

Work AreaGood lighting and an elevated table will help you gain accessto all of the mounting hardware and accessories of the hand-held generator. Certainly, larger is better but a goodminimum sized table would be 20in. by 30in. If casters areapplied to the legs of the table, be sure they are secure andsturdy enough to support not only the generator but alsothe work being performed.

Hand ToolsA minimum collection of standard mechanic's hand toolsshould include:

· 3/8" drive socket set (SAE)

· 3/8" drive socket set (Metric)

· A 3/8" drive ratchet

· 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

Special ToolsElectronic Measuring Equipment:

The measuring equipment used in troubleshooting should beof industrial quality and have the sensitivity to measureelectronic values to the third decimal. Its accuracy should bewithin acceptable tolerances should have the ability tomeasure capacitance.



Figure 6 — Fuel Systems Components

Shut-Off Valve

Fuel Hose

Fuel Cap Assembly

Fuel Strainer

Spill Well

TankMounting Brackets

Tank Sump Filter

Figure 7 — Fuel Cap Assembly

1

13

Section 2 • Disassembly


DISASSEMBLY 2

14

Disassembly • Section 2


2

15

General Disassembly ConsiderationsAlways inspect the external condition of the plasticcomponents before disassembling the unit. Look for cracksand broken plastic and be sure to note these conditions asexisting before maintenance is undertaken.

Hand-held generators are built to close tolerances. Thefasteners used to hold the plastic shrouds and covers arespecial machine screws that have a "pilot" collarincorporated into the grip area of the screw (Figure 8).

NOTE: When assembling plastic components, besure the "collar" of the screw fits into the opening ofthe shroud or cover. Pinching the plastic under thecollar will break the plastic at the mounting locations.

The length of these fasteners is critical to the properassembly of the unit. When disassembling the generator, it isrecommended that the location and length of each fastenerbe noted.

When troubleshooting becomes necessary, access to variouscomponents, systems and structural members is required.Regardless of the ultimate reason, a clear understanding ofthe unit's disassembly will save time and effort.

NOTE: Do not attempt to remove the protectivegrill that surrounds the exhaust muffler. The fastenersthat hold it in place are secured with plain nuts andlock-washers. If you attempt to remove the grill, itwill be necessary to disassemble the case halves inorder 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 filterassembly to the carburetor (Figure 48, Pg. 34).

• Remove the two screws that hold the handle of theunit together (Figure 9).

At this point, position the unit so you are facing the mufflerside of the generator.

• Remove only those fasteners that hold the rear casehalf. That is:

• Those screws around the lower base of the rearof the generator.

• The upper screws that secure the rear case-halfon the right and left side of the generator.

• Grasp the rear case half and gently separate it from thegenerator unit.



Figure 8 — Screws with ”Pilot Collar”

Pilot Collars

Figure 9 — Remove Screws In Handle

2

16

• Remove the screw that is next to the fuel shut-off valveand retain the mounting bracket that supports the fueltank (Figure 10).

• Slide the fuel tank out of its cradle and remove the fuelsupply hose from the bottom of the tank (Figure 11).



Figure 10 — Mounting Bracket Screw

Figure 11 — Remove Fuel Supply Hose

Hose to Tank

2

17

NOTE: At this point, you have visual access tomany of the mechanical and electronic components ofthe generator (Figure 12).

Many individual electronic components are supported byclips and brackets that are molded parts of the front casehalf. This disassembly procedure assumes you are seekingaccess to the engine and generator for overhaul purposesand the components that are held by the case will be left intheir mountings.

• Position the unit so you are facing the front of thegenerator.

• Remove the screws around the base.

• Separate the electrical connectors at locations shown inFigures 13A and 13B.

• Set the front case-half aside.

ACCESS TO GENERATOR COMPONENTS



Figure 12 — Access To Generator Components

Figure 13 — Generator Components

A BHarness Connectors

2

18

This provides sufficient access to the generator unit fortroubleshooting, component replacement and overhaul(Figure 14).

A view of the electrical components that are mounted onthe inside of the front case-half is provided in Figure 15.

Rotor / Stator Removal•• Step 1:

• For easier access, position the unit as shown in figure 16.

•• Step 2:

Remove the cooling fan as shown. (Figure 17).

NOTE: Mark the face of the fan to ensure properreassembly.



Figure 14 — Generator Unit Exposed

Figure 15 — Electrical Components Mounted On Case

Figure 16 — Position For Rotor Removal / Inspection

Figure 17 — Remove Cooling Fan

2

19

•• Step 3:

• Remove the heat shield mounting screws (Figure 18A).

•• Step 4:

• Remove the rear bearing carrier mount bolts (Figure 18B).

•• Step 5:

• Remove the three through-bolts (Figure 19).

•• Step 6:

• Remove the rear bearing carrier and the statortogether (Figure 20).



Figure 18 — Hardware (Heat Shield / Stator Housing)

Figure 19 — Remove Stator Through-Bolts

A B

Figure 20 — Remove Stator Housing & Stator

2

20



2

21

Section 3 • Troubleshooting


TROUBLESHOOTING 3

22

Troubleshooting • Section 3


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)

Figure 21 — Under-Voltage (DC) Troubleshooting Flow Chart

Test ACheck Engine RPMSee Appendix

OK? Repair/ReplaceSee B&S #272147

NO DCOK?

YES

YES NO

Test BCheckReceptacleWiring

OK? Repair/ReplaceSee Page 25

NO DCOK?

YES

YES NO

Test CCheck DCCircuitBreaker


NO DCOK?

YES

YES NO

Test DCheck BridgeDiode


NO DCOK?

YES

YES NO

Test ECheck 12VDCCoil


NO DCOK?

YES

YES NO

Test FCheck RotorWinding


NO DCOK?

YES

YES NO

END

3

23



Test C: - Check (DC) Circuit Breaker

•• Step 1:

• Remove the three screws that secure the control panelto the face of the generator unit.

•• Step 2:

• Remove both the terminals at the back of the circuitbreaker (Figure 22A).

•• Step 3:

• With the circuit breaker ON and your VOM set toohms, check for continuity at the terminals of thecircuit breaker (Figure 22B).

- Continuity = Circuit Breaker OK

- No Continuity = Defective Circuit Breaker.

Replace Circuit Breaker

Test D: - Check Bridge Diode

With the control panel still removed:

•• Step 1:

• Locate and separate the harness connector that has thetwo brown wires. Push the male half of the connectoraside.

NOTE: You must follow the Diode Testinstructions that are provided with the meter you areusing.

•• Step 2:

• Using the female terminals of the brown wires and thepositive output terminal of the cigarette lighter, or theDC receptacle, you can check continuity of the bridgediode wiring (Figure 23).

Test E: - Check 12VDC Coil

With the control panel still removed:

•• Step 1:

• Locate and separate the harness connector that has thetwo brown wires coming.from the stator.

•• Step 2:

• With your VOM set to ohms, read the coil resistanceat the terminal of the brown leads in the connector(Figure 24).

•• Step 3:

• Compare readings with resistance values in theapppendix.

Test F: - Check Rotor Winding

(See Test G on )

Figure 22 — Checking (DC) Circuit Breaker

Figure 23 — Checking The Bridge Diode

Yes Yes Yes(+) ~1 ~2 (-)

~1 No No Yes~2 No No Yes(-) No No No

Negative Probe (-)

Po

siti

ve P

robe

(+)

(+)

Figure 24 — Reading 12VDC Coil Resistance

A B

Brown

3


"Over Voltage" (AC)Refer to Figure 25 ("Over Voltage (AC)" Flow Chart) abovefor the sequential steps involved with this procedure. Toseparate the case halves, see page 13.


(See Appendix)

Test B: - Check Capacitor

The capacitor can be checked without disassembling the unitcase-halves.

•• Step 1:

• Remove the three screws that secure the control panelto the face of the generator unit (Figure 26).

•• Step 2:

• Disconnect the harness connector that has the twoyellow wires.

•• Step 3:

• Using a jumper wire, (Figure 27) short the two yellowterminals that come from the capacitor. Then removethe jumper wire.

24


Figure 25 — Over-Voltage (AC) Troubleshooting Flow Chart

Figure 26 — Remove Control Panel


OK?Test BCheckCapacitor

Repair/ReplaceSee Page 22

OK?

ACOK?

ACOK?

END

Repair/ReplaceSee B&S #272147

YES

YES

YES

YES

NO

NO

NO

NO

3

25



•• Step 4:

• Refer to the owner's manual of your VOM and test thecapacitor according to the directions for yourequipment.

• Find the rating of the capacitor on its body or in theappendix of this manual.

• Compare reading with the stated value .

Replace the capacitor if it is found to be faulty.

Figure 27 — Short the Capacitor Terminals

Figure 28 — Testing the Capcitor

Yellow

3

26



Figure 29 — Under-Voltage (AC) Troubleshooting Flow Chart


OK? Repair/ReplaceSee B&S #272147

NO ACOK?

YES

YES NO

Test BCheckReceptacleWiring


NO ACOK?

YES

YES NO

Test CCheck ACCircuitBreaker


NO ACOK?

YES

YES NO

Test DCheck StatorPowerWinding


NO ACOK?

YES

YES NO

Test ECheckCapacitor


NO ACOK?

YES

YES NO

Test FCheckExcitationWinding


NO ACOK?

YES

YES NO

Test GCheck RotorWinding


NO ACOK?

YES

YES NO

END

3



27

Under Voltage (AC)Refer to Figure 29 ("Under Voltage (AC)" Flow Chart) onthe preceding page for the sequential steps involved withthis procedure. To separate the case halves, see page 13.


(See Appendix)

Test B: - Check Receptacle Wiring

•• Step 1:


•• Step 2:

• Test the receptacle for:

- Shorted contacts.

- Burned or cracked insulation material.

- Faulty terminal screws (Figure 30).

•• Step 3:

• If any faults are found,

- Replace receptacle.

Test C: - Check AC Circuit Breaker

•• Step 1:

Remove both the terminals at the back of the circuitbreaker (Figure 31A).

•• Step 2:

• With the circuit breaker CLOSED and your VOM setto ohms, check for continuity at the terminals of thecircuit breaker (Figure 31B).

- Continuity: = Circuit Breaker - OK

- No Continuity: = Defective Circuit Breaker.

Replace Circuit Breaker

Figure 30 — AC Receptacle

Figure 31 — Checking Circuit Breaker

3

28



Test D: - Check Stator Power Winding

•• Step 1:

• Disconnect the 4-pin harness connector that containsthe yellow wires.

•• Step 2:

• On the male portion of the connector, locate the pinsthat connect the blue and red wires (This harnessshould be coming from the generator stator assemblysee figure 32).

•• Step 3:

• With your VOM set to ohms, measure the resistanceacross the blue and red wires that come from thestator (Figure 32).

• Compare reading with the resistance values in theappendix.

- Within tolerance: Power winding is good

- Exceeds tolerance: Replace Stator

Test E: - Check Capacitor

(Page 22)

Test F: - Check Excitation Winding

•• Step 1:

• Disconnect the harness connector that contains theyellow wires.

•• Step 2:

• On the male portion of the connector, find the pinsthat connect the two yellow wires (This harness shouldbe coming from the generator stator assembly seefigure 33).

•• Step 3:

• With your VOM set to ohms, measure the resistanceacross the two yellow wires that come from the stator(Figure 33).

• Compare reading with the resistance values in theappendix.

- Within tolerance: Excitation winding is good

- Exceeds tolerance: Replace Stator

Figure 33 — Checking Excitation WindingFigure 32 — Checking Stator Power Winding

3

29



Test G: - Check Rotor Winding

The rotor is considered a non-serviceable part because it isa sealed unit that would require disassembly to properlytest. Therefore, it is by process of eliminating all otherpossible faults that the rotor can be considered faulty.

NOTE: Piercing the red or blue wire and checkingacross the terminal post of the rotor diode is notrecommended.

Before rotor replacement, follow the checklist outlinedbelow:

• 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

Engine Switch•• Step 1:


•• Step 2:

• Remove the terminals from the switch.

•• Step 3:

• With your VOM set to ohms, cycle the switch to ONand test for continuity (Figure 34).

- You should have continuity.

•• Step 4:

• Cycle the switch to OFF.

- You should not have continuity.

Figure 34 — Checking The Engine Switch

3

30



Pilot LampSome early units were equipped with a green pilot lamp. Ifthis is the case, troubleshoot the lamp using the instructionsthat follow;

•• Step 1:


•• Step 2:

• Remove the terminals from the lamp.

•• Step 3:

• With your VOM set to ohms, check for continuitythrough the lamp (Figure 35).

- No continuity: Replace lamp.

Figure 35 — Checking The Pilot Lamp

3

31

Section 4 • Assembly


ASSEMBLY 4

32

Assembly • Section 4


4

33



Mounting The Rotor & StatorPosition the generator/base plate assembly as shown infigure 36, before mounting the stator assembly.

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

NOTE: The rotor is not timed in any way.

• Position the stator and the rear bearing carrier overthe rotor and align the feet with the mounting holes inthe base plate (Figure 38).

• Install the bolts but do not tighten yet.

Make sure the stator is seated in the machined lands of itscradle as shown in figure 39A and 39B.

With the stator properly seated in the machined lands of itscradle:

Figure 36 — Generator / Base Plate Assembly

Figure 37 — Mount The Rotor

Figure 38 — Positioning The Stator

Figure 39 — Seating The Statot Assembly

4A B

34



• Install the three stator through-bolts and tighten untilthe rear bearing carrier is secure (Figure 40).

• Check to make sure there are no obstructions to therotation of the rotor assembly.

• Torque the through bolts to 85 lbs. in.

• Torque the mounting bolts in the feet of the rearbearing carrier to 180 lbs. in.

• Slip the rotor mount bolt through the cooling fan. Startthe bolt in the threads of the engine output shaft byhand (Figure 41).

Before tightening the rotor mount bolt:

• Check the orientation of the fan (Figure 42).

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 bearingcarrier align with the mounting flange of the heat shield (Figure 43A & 43B).

Figure 40 — Securing The Stator Assembly

Figure 41 — Installing Rotor Mount Bolt

Figure 42 — Cooling Fan Orientation

Figure 43 — Generator Heat Shield

A B

4

35


• Install the mounting screws and tighten until the heatshield is secure.

NOTE: Make sure that the bent angles of the heatshield are in contact with surfaces of the engine asshown in figure 44.

Check to make sure that all the mounting hardware is tightand secure.

Connecting The Wiring HarnessThe control panel that is mounted in the front case half isconnected to the generator by means of two four-pin cableconnectors. The associated wires colors are identical.

• Match the wire colors of the two harness connectorsand seat each connector until it locks into place (Figure 45).

• Connect one lead of the engine run switch to theengine ground wire.

• Connect the other wire from the engine run switch tothe connector that also houses the blue wire from theignition coil (Figure 46).

Figure 44 — Check Heat Shield Contact And Mounting

Figure 45 — Harness Connectors


Figure 46 — Ground And Run Switch

4

36


Mount The Rear Case Halve• Position the unit as shown in figure 47.

• Mount the air cleaner housing to the two studs thatextend through the carburetor (Figure 48A).

• Insert the oil breather hose into the back of the air cleanerhousing (Figure 48B).

NOTE: Make sure that the steel bushings areinstalled in the housing for the air cleaner (Figure 48A).

The rear case half is mounted on the carriage first.

• Align the rear case half with the mounting holes in thegenerator carriage.

• Refer to figure 49A & B and place the fasteners as shown.

The tank support brackets are shown in figure 50A & B.

• Insert the left-hand tank support bracket inside the casestiffener and secure to the rear case half with a M5-16screw with a medium pilot collar (Figure 50A).

• Mount the right hand bracket as shown in figure 50B.


Figure 47 — Unit Positioned For Closure

Figure 48 — Breather Tube & Air Filter Housing

Figure 49 — Rear Case Half Fasteners

A B

M6-16

M6-20 M6-20

A B

Figure 50 — Fuel Tank Support Brackets

A B

M5-164


37

Mount The Fuel TankInspect the tank for the following items;

• Ensure that the fuel strainer is installed in the bottom ofthe tank sump.

• Check that the rubber vibration seals are glued on theseams of the fuel tank.

• Seat the tank in the area above the support brackets(Figure 51).

• Connect the fuel supply hose to the tank as shown infigure 52.

Mount The Front Case HalfBefore mounting the front case half, ensure that the LOSmodule is oriented on its mounting as shown in figure 53.

• Position the front case half close enough to the generatorunit in order to make the wiring connections to the LowOil Sense (LOS) module and start switch (Figure 54).


Figure 51 — Mounting The Fuel Tank

Figure 52 — Connecting The Fuel Supply Hose

Figure 53 — LOS Orientation

Figure 54 — Start Switch & (LOS) Wiring

4

38


• Route the starter rope through its opening in the case.

• Align the front case half with the mounting points in thegenerator carriage and install the fasteners (figure 55).

With the mounting fasteners tight, connect the wiringharness connectors through the opening of the controlpanel (Figure 56).

• Match the colors of the wires.

NOTE: Match the color-coding of the wires tomake sure that you are making the properconnections (Figure 57).

• Install the control panel face plate (Figure 58).

• Install oil service cover (Figure 59).


Figure 55 — Fastener Locations On Front Case Half

Figure 56 — Access To Wiring Harness

Figure 57 — Wiring Harness Connections

Figure 58 — Install Control Panel

4

39


• Install air filter assembly (Figure 60).

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


Figure 59 — Install Oil Service Door Figure 61 — Install Spill Well & Fuel Cap

Figure 60 — Install Air Filter Assembly

4

40



4

41

Section 5 • Appendix


APPENDIX 5

42

Appendix • Section 5


5

43

Resistance Values

Rotors:

(60HZ) 4.06 ohm

(50HZ) 4.10 ohm

Stators:

(60HZ)

Excitation Winding 3.911 ohm

Power Winding 1.010 ohm

12VDC Winding .429 ohm

(50HZ)

Excitation Winding 4.79 ohm

Power Winding 4.33 ohm

12VDC Winding .510 ohm

Capacitors:

(60HZ) 14 µFu

(50HZ) 14 µFu

APPENDIX



Torque Specifications

Engine:

Item Size Torque Value (In. Lbs.)

Connecting Rod M6x30 85

Crankcase Cover M6x12 85M8 180

Muffler M8 180

Head Bolt M8x55 220Flywheel Nut M12 400

Spark Plug M14 180

Oil Drain Plug M10 180

Cooling Fan 5/16" 85

Pivot Bolt M8 180

General Screws M5 35Rocker Arm Assy. M6x16 45

M8 180

CT Bolt M6 85

M8 180

Rocker Box Cover M6x12 45

Generator:

Rotor Bolt M6 100

Stator Bolt M6 85

Tapping Screw M6 45

General Screws M4 20

M5 35

M6 45

M8 180 5

44

M6-16M6-20

M6-20

M5-10

M5-10

M5-16

M5-16

M6-16

M6-16

M6-16



5

Figure 62 — Fastener Sizes and Locations

45



M6-90

M8-12

M8-12

M8

Self-Tapping Screw

M8-12

M6-160

5

Figure 63 — Fastener Sizes and Locations (Continued)

46



5

190275gs hand held generators

Documents

sequential

rear bearing

latest production

stratton corporation

engine driven

fuel supply

rear case

drive socket