Briggs & Stratton 86262GS Familiarization & Troubleshooting Manual
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Briggs & Stratton 86262GS Familiarization & Troubleshooting Manual

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Summary of Contents for Briggs & Stratton 86262GS

  • Page 1 For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983 Familiarization & Troubleshooting Guide GENERATOR www.mymowerparts.com...
  • Page 2 F F O O R R W W A A R R D D 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.

  • Page 3: Table Of Contents

    Portable Generator Familiarization & Troubleshooting Guide Table of Contents GENERAC PORTABLE PRODUCTS ® Generator Generator Components Fundamentals And Systems Basic Electricity Generator Components Magnetism and Electricity Rotor Assembly Electro-Motive Force Stator Assembly Electromagnetism Switches Direct Current (DC) Fuses Alternating Current (AC) Circuit Breakers Volt Solenoids...
  • Page 4 Portable Generator Familiarization & Troubleshooting Guide Table of Contents GENERAC PORTABLE PRODUCTS ® Generator Diagnostics And Appendix A Adjustments Generac® Torque Table Troubleshooting Idle Controls Generac® Receptacles And Plugs Troubleshooting Flowchart For “Direct Excited” (Brush Type) Glossary Generators Troubleshooting Flowchart For (Brush Type) Generators With “Two Board”...

  • Page 5: Generator Fundamentals

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals BASIC ELECTRICITY The Atom Borrowing Of Electrons All matter is made up of atoms. An atom may be compared If an atom loses electrons, the positive (+) charge of the to a solar system that has several planets revolving around nucleus and the negative (-) charge of the electrons the sun.There are more than 100 different kinds of atoms.

  • Page 6: Electro-Motive Force

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals The difference between conventional and electron theories Electrical current flow is based on the is mentioned because the conventional theory is more principle: commonly used in everyday applications. For this guide, That atoms have the ability to readily however, we will use the Electron Theory.
  • Page 7 Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals CREATING CURRENT FLOW Several basic methods may be used to create an electrical Figure 1.5 — The Thermocouple current flow. Four methods will be discussed here. All of these methods are based on a fundamental law that energy can never be created or destroyed but can be changed into other forms of energy.Thus, chemical, heat, light and magnetic energy can be changed into electrical energy.
  • Page 8 Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals Magnetic “lines of force” surround a magnet.These lines of Figure 1.7 — The Right Hand Rule force are concentrated at the magnet’s NORTH and SOUTH poles and are often called “lines of flux” (Figure 1.6).

  • Page 9: Electromagnetism

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals Electromagnetic Induction Figure 1.10 — Typical Automotive Ignition System In 1831, scientists observed that a conductor moving through a magnetic field would have a voltage or electro- motive force (EMF) induced into itself. Electromagnetic induction may be defined as the action of inducing of a voltage into a conductor by moving it through a magnetic field.This principle is illustrated in Figure 1.9.

  • Page 10: Direct Current (Dc)

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals If the coil is wound around a core of magnetic material, such Figure 1.13 — Example of “Ampere-Turns” as iron, the strength of the magnetic field at the north and south poles is greatly increased (Figure 1.12).
  • Page 11 Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals The flow of electrons changes direction according to the rotating armature's position in relation to the poles of a magnetic field (See the Table 1.1). Table 1.1 — Current Flow Pattern A wave diagram (sine wave) of alternating current shows that current goes from a zero value to maximum positive value (0°- 90°...

  • Page 12: Volt

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals UNITS OF ELECTRICAL MEASUREMENT Just as a hydraulic system must have specific values: Figure 1.16 — Electrical Measurement Units • Rate of flow. • Pressure. • Resistance to flow. Relavent established values can also be expressed for an electrical circuit.

  • Page 13: Ohm's Law

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals A conductor’s resistance depends on: Figure 1.17 — Ohms Law Expressed Mathematically • Its construction. • It’s cross-sectional area. • It’s length. • It’s temperature. One ohm is the amount of resistance that will permit one ampere of current to flow in a conductor when one volt of electro-motive force is applied.

  • Page 14: Electrical Formulas

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals ELECTRICAL FORMULAS...

  • Page 15: The Series Circuit

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals ELECTRICAL CIRCUITS Electrical conductors and resistances (loads) can be arranged Figure 1.19 — The Series Circuit to form any of three following types of circuits: • A Series Circuit •...

  • Page 16: The Series-Parallel Circuit

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals Resistance in a parallel circuit is less than the resistance of 3-Wire Circuit any of the individual branches or paths.To find total Many buildings and AC alternators that have a single phase resistance in any parallel circuit, use the following formula: output are connected in a 3-wire circuit (Figure 1.22).The 3-wire circuit provides “dual voltage,”...
  • Page 17 Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals A 3-phase circuit has the following advantages: The 3-phase connection systems or circuits may be: • When the load is balanced in all three legs of a • Wye-Connected 3-phase circuit, instantaneous power is constant.This •...
  • Page 18 Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals Figure 1.26 — Some Examples of 3-Phase Connection System...

  • Page 19: Simple Alternator

    Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals SIMPLE ALTERNATOR OPERATION Simple Alternator The Revolving Magnetic Field In an alternator (Figure 1.27), a revolving magnetic field The rotor is essentially an electro-magnet.The flow of called a rotor is moved through a stationary coil of wires direct current (DC) through its windings creates a magnetic called a stator.This movement induces an electro-motive field around the rotor core (Figure 1.28).The strength of this...
  • Page 20 Portable Generator Familiarization & Troubleshooting Guide Section 1 • Generator Fundamentals...

  • Page 21: Generator Components

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems GENERATOR COMPONENTS Introduction “guesswork” while troubleshooting is not cost effective and Portable generators do not have a large number of parts. should be avoided. Figure 2.1 is an exploded view of a typical However, these parts are expensive and should not be portable generator set.

  • Page 22: Rotor Assembly

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Engine Assembly Rotor Assembly As a general rule, the engine must deliver approximately 2 A pre-lubricated and sealed ball bearing is pressed onto the horsepower for each 1000 watts (1.0 kW) of generator rotor shaft.

  • Page 23: Stator Assembly

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Two-Pole Rotors: Figure 2.4 — Typical Stator Assembly A 2-pole rotor has a single north and a single south magnetic pole. One revolution of the 2-pole rotor creates a single cycle of alternating current flow in the stator windings.
  • Page 24 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Figure 2.6 represents a “dual voltage” stator (AC) power Stator Excitation Winding winding schematic. Direct Excited Units: Excitation winding (AC) output is delivered to a bridge rectifier (Figure 2.8), which converts its It is made up of two windings and has the ability to supply a output to direct current (DC).

  • Page 25: Switches

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems NOTE: Switches During tests, this type of stator will show “continuity” between the (AC) power and (DPE) A switch may be defined as a device used to open, close or windings.
  • Page 26 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Figure 2.12 — Single Pole, Single Throw (SPST) Figure 2.15 — Double Pole, Double Throw (DPDT) Figure 2.13 — Single Pole, Double Throw (SPDT) Figure 2.16 — Three Pole, Double Pole (3PDT) Figure 2.17 —...
  • Page 27 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Push Button Switches Figure 2.19 — Some Typical Rotary Switches Push button switches may be classified generally as “normally-open” (NO) or “normally-closed” (NC) type switches. Both types are illustrated in Figure 2.18. Figure 2.18 —...

  • Page 28: Fuses

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Protective Switches Figure 2.22 — Typical Circuit Breakers Fuses A fuse could be called a switch because it functions to open an electrical circuit when current flow becomes excessive. The fuse in Figure 2.21 is a strip of metal with a known melting point that has been installed in series with the circuit it is meant to protect.

  • Page 29: Solenoids

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Some stators may have a thermal protector imbedded in Figure 2.25 — Typical Pressure Switch their wire windings and electrically connected in series with the excitation winding output to the voltage regulator.This thermal switch opens at a pre-determined temperature to terminate excitation current output to the rotor.The switch closes automatically when the internal stator temperature...

  • Page 30: Relays

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Engine Throttle Control Figure 2.28 — Construction Of A Typical Relay Some generator units may be equipped with an automatic idle (throttle) control device. This device uses a solenoid to pull the carburetor throttle lever against its idle stop when the alternator unit is not powering any electrical loads.

  • Page 31: Resistors

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Resistors Figure 2.32 — Typical Rheostat Resistors are used to introduce resistance into a circuit, thereby limiting current flow. Resistance is dependent upon the length, cross sectional area, and physical properties of a conductor.These factors are used in the construction of resistors.
  • Page 32 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems The Varistor Varistors are unique types of resistors that present high resistance to normal voltages and a low resistance to excessive voltages in circuits.You could call them “voltage- sensitive.

  • Page 33: Transformers

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Transformers through the primary winding increases, which expands lines A transformer increases (steps up) or decreases (steps of magnetic force that cut across the secondary winding.This down) an applied voltage.Transformers use the principles of causes a voltage to be induced into the secondary winding in electromagnetic induction and, more precisely, mutual one direction.

  • Page 34: Condensers

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Condensers Figure 2.37— Charge and Discharge of a Condenser The terms “condensers” and “capacitors” may be used interchangeably.They are electrical devices that store energy within themselves (Figure 2.36). A simple condenser (capacitor) consists of two metal plates separated by a small air space or a layer of insulating material called a “dielectric.”...

  • Page 35: Rectifiers

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Rectifiers Figure 2.39 — Typical Blocking Diodes Rectifiers, also known as diodes, are used to convert alternating current (AC) to direct current (DC). A simple rectifier consists of a thin film of metallic oxide which is deposited on a thicker plate of metal, such as iron.

  • Page 36: Transistors

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Silicone-Controlled Rectifiers Figure 2.42 — The Zener Diode The silicone-controlled rectifier is often referred to as simply an “SCR” (Figure 2.41). The SCR permits current to flow in one direction when a voltage is applied at its “gate.”...

  • Page 37: Brushes And Brush Holders

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems It might also be a wafer of “P-Type” material sandwiched Brushes and Brush Holders between two sections of “N-Type” material.The thin part of The brush holder is usually attached to the rear bearing the transistor is called the base.The left portion is the carrier.The positive (+) brush rides on the slip ring nearest emitter.The portion on the right is the collector.
  • Page 38 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Early production units were equipped with a plug-in type More recent units are equipped with a rectifier and brush rectifier that plugged into the top side of the stator holder assembly, shown in Figure 2.49.

  • Page 39: Voltage Regulator

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems The rotor may be considered a permanent magnet since Figure 2.52 — Voltage Regulator some residual magnetism is always present.The stator has two coils of wire. One is called an “excitation winding” and the other is called the “power winding.”...
  • Page 40 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Some generators employ an electronic voltage regulator to Solid State Voltage Regulation “regulate” current flow to the rotor windings (Figure 2.54). This type of voltage regulator is often called a “Voltage-over-Frequency”...
  • Page 41 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Figure 2.55 — Operating Diagram (“Voltage Over Frequency”) through the rotor results in a proportional increase or Figure 2.56 — Power Regulator Circuit Board decrease in the rotor’s magnetic field strength, which is what induces (AC) current in the output windings of the stator.

  • Page 42: Receptacle Panel

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Some portable generators, such as the “XL” and “MC” Other models employ a separate receptacle panel.When series, are equipped with a power regulator circuit board electrical receptacles are mounted on the bearing carrier and a system control circuit board (Figure 2.58).

  • Page 43: Generator Systems

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems GENERATOR SYSTEMS Battery Charge Circuits Figure 2.62 — Electric Start Unit Some portable generators may have battery charge capability. If so, the stator assembly will include a battery charge winding in addition to the (AC) power and excitation (DPE) winding.With the engine running, a charging current will be delivered to the unit’s starting battery (electric start...

  • Page 44: Revolving Field Excitation Methods

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Revolving Field Excitation Methods • Winding “B” is the Direct Excitation Winding.The EMF induced into this winding produces an alternating Up to this point, we have observed the following: current flow, which is applied to a Bridge Rectifier.
  • Page 45 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems The alternating current flowing through the primary • The (AC) output to the load (using reactor excitation) windings creates a magnetic field which cuts through the is taken from the same stator winding that the secondary coil thereby inducing a current flow into the excitation current is taken from (instead of having an secondary windings.

  • Page 46: The Brushless Excitation Method

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems The Brushless Excitation Method That induces an (AC) voltage in the rotor winding that is converted to a (DC) voltage by a diode in the rotor winding. As the engine spins the rotor, residual magnetism induces an This creates an electromagnet in the rotor assembly.

  • Page 47: Field Boost Assembly

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Field Boost Assembly “Field Boost” operation may be briefly described as follows: • During start up, residual (AC) voltage is delivered to the Some types of voltage regulators require approximately (PTC) and diode from the stator power winding.

  • Page 48: Power Factor

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Each time the magnetic field around an (AC) conductor Such a condition would exist when a reactance condition collapses, a voltage (EMF) is induced into that conductor.This occurs in a circuit.
  • Page 49 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Figure 2.73 — Determining The Power Factor...
  • Page 50 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems A TYPICAL LOW OIL LEVEL Should the engine oil level drop below a specified level, the switch will actuate and ground the engine ignition circuit, SYSTEM causing the engine to shut down. If the oil level is low, the Figure 2.74 is typical of the low oil level shutdown system light will flash while the engine is cranking.To reset the float used on Briggs &...

  • Page 51: Oil Pressure Switch On "Gn" Engines

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Figure 2.77 — V-Twin Engine’s Time Delay Relay Figure 2.79 — “XL” Series Oil Pressure Switch However, the functions of the time delay relay are built into The V-Twin engine’s low oil pressure circuit is shown a system control circuit board (Figure 2.80).

  • Page 52: Typical Automatic Idle Control System

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Typical Automatic Idle Control Figure 2.82 — Idle Control Coil And Flapper System Some portable generators may be equipped with an automatic idle control system. Such a system provides greatly improved fuel economy by running the engine at normal governed speed only when electrical loads are plugged in and turned on.When electrical loads are...

  • Page 53: Early V-Twin Engine Idle Control

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Operation of the idle control system may be briefly Two solenoid mounting brackets are retained to the fuel described as follows: tank heat shield.The brackets are slotted to permit axial adjustment of the idle control solenoid.The solenoid, along •...
  • Page 54 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems Figure 2.87 shows the idle control transformer which is • When electrical loads are applied to the generator, housed in the generator control panel. current will flow through the transformer’s primary windings, inducing a current in the secondary windings.

  • Page 55: Xl And Mc Idle Control On 480 & 570 V-Twin Engines

    Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems XL And MC Idle Control On 480 & 570 V-Twin • Current does not flow through the primary windings of Engines the idle control transformer and no current flow will be induced into the transformer’s secondary windings.
  • Page 56 Portable Generator Familiarization & Troubleshooting Guide Section 2 • Generator Components & Systems...

  • Page 57: Generator Diagnostics And Adjustments

    Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments GENERATOR DIAGNOSTICS AND ADJUSTMENTS Safety Practices • Never handle any kind of electrical cord or device while • Generator exhaust gases contain DEADLY carbon standing in water, while barefoot, or while hands or feet monoxide gas.This dangerous gas, if breathed in are wet.

  • Page 58: Troubleshooting Idle Controls

    Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments TROUBLESHOOTING IDLE CONTROLS Figure 3.1 — Idle Control Troubleshooting Flow Chart (3500-7500 Watt Generators) control...
  • Page 59 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments XL&MC Generators, 3500-7500 Watt Figure 3.2 — Check System Control Board Input Refer to Figure 3.1. Test 1: — Check (AC) Frequency and Voltage Connect an accurate (AC) frequency meter across the two parallel blades of one of the panel 120VAC receptacles.
  • Page 60 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Test 4: Test 5 — Check System Control Board Output — Check Idle Control Coil Measure the (DC) voltage across the two BLK wires on the Remove the five pin connector from the system control system control board.These wires go to the idle control coil board.
  • Page 61 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments...
  • Page 62 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Figure 3.4 — Idle Control Troubleshooting Flow Chart (480 & 570 V-Twin GN Engines 8000-10000 Watt Generators...
  • Page 63 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments XL&MC Generators, 8000-10000 If the unit does produce (AC,) but (DC) voltage is not present at pins J2 and J3, check for a failure in the battery Watt charge circuit of the generator.
  • Page 64 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments NOTE: • To the BROWN wire connector pin. To get an accurate measurement, you may Approximately 10 ohms. need to keep turning the idle control switch on and off in order to keep the stepper motor •...
  • Page 65 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Connect an accurate (AC) frequency meter to one of the With the engine running at correct idle speed: generator receptacles. • Turn the idle mixture valve in (lean) until the engine Then, complete adjustments as follows: begins to roughen and then out (rich) until it roughens.
  • Page 66 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Adjustment at “No Load” Frequency Refer to Figure 3.12. Perform steps with the engine running at its correct “no-load” frequency. Check that all springs and linkages are properly installed.The capscrews that retain the solenoid mounting brackets to the Then proceed as follows: fuel tank heat shield must be tight.Then connect an (AC)

  • Page 67: Generators

    Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Adjustment at “Low Idle” Frequency Figure 3.14 — Idle Mixture Adjustment NOTE: The “Low Idle” Frequency adjustment should only be done after successfully completing “No Load” and “Rated Load” adjustments. With the unit running and no loads connected to the generator: •...
  • Page 68 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments GN-190, 220, 320 , 360 & 410 Figure 3.15 — Idle Control Solenoid Engine Idle Control Idle speed adjustments consist of first adjusting the position of the idle control solenoid to maintain approximately 40-45 Hertz (2100 rpm).
  • Page 69 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Adjusting Idle Control 8KW EXL & 10KW EXL Back out both high and low speed adjustment screws several turns. • Turn idle switch OFF. • Start engine and allow to run at “no load” until stabilized and warmed up.
  • Page 70 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments TROUBLESHOOTING GENERATOR UNITS Figure 3.17 — Troubleshooting Flow Chart For “Direct Excited” (Brush Type) Generators or later.
  • Page 71 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Troubleshooting “Direct Excited” If the unit is equipped with a voltage regulator or a bridge rectifier, flash the field as follows: (Brush Type) Generators • Obtain a 12VDC battery. Refer to Figure 3.17 •...
  • Page 72 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments If the unit is equipped with a brush/bridge rectifier (refer to To test the rotor with a volt-ohm-milliameter VOM, set the Figure 3.19), proceed as follows: VOM to its “OHM” scale and zero the meter.Then, test for an open, shorted or grounded condition as follows: Figure 3.19 —...
  • Page 73 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Measure the rotor resistance and compare it to the nominal • Connect a jumper wire between the negative brush and resistance from the appropriate resistance table (Briggs & the negative post on the battery ®...
  • Page 74 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Test 5 : — Check Stator Excitation (DPE) Windings Figure 3.25 — Testing For Short Between Windings NOTE: The excitation wires may be colored or numbered.The numbered wires are #2 and #6.The colored wires are blue and red.
  • Page 75 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Test 6: • Connect one meter test lead to a good ground. — Testing Stator AC Power Windings Connect the other test lead to the stator power Testing Single Voltage Type Power Winding winding (Figure 3.28).
  • Page 76 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Testing Battery Charge Windings • Start the generator (make sure the remaining wires are not touching each other or the control panel, etc.). • Set VOM to “OHM” scale. Measure (AC) output across sensing wires #11 and #22 (on If a single winding is used: voltage regulator types only).
  • Page 77 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Analyze the test results as follows: If any of the (AC) voltage readings are below 60VAC (slightly higher is ok) and rotor current draw is within specification: •...

  • Page 78: Two Board" Regulation

    Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Figure 3.31— Troubleshooting Flow Chart For (Brush Type) Generators With “Two-Board” Regulation...
  • Page 79 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Troubleshooting “Two Board” If the unit is equipped with a voltage regulator or a bridge rectifier, flash the field as follows: Regulation Generators (Brush • Obtain a 12VDC battery. Type) •...
  • Page 80 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Test 3: — Isolate the System Control Board Figure 3.34 — Installing Jumper Wire Locate the power regulator circuit board inside the rear bearing carrier.This board is similar to the bridge rectifier on some other models.
  • Page 81 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments If the leads are not in the correct position as noted in Measure the voltage at the excitation wire #2 and #6 (blue Figure 3.35: and red). At least 60VAC should be measured. Measure the voltage at the 120VAC receptacle.
  • Page 82 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Before testing the rotor, inspect the brushes and slip rings. Figure 3.38 — Access To Rotor Slip Rings Replace brushes if they are worn excessively, or if they are cracked or damaged.
  • Page 83 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments To diagnose, use the “Rotor Current Draw Test.” Analyze the test results as follows: If the rotor current draw is higher than specified, a flying •• Step 2 Rotor Current Draw Test short exists in the rotor.
  • Page 84 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments • Connect one test lead to a stator power wire. Connect A reading of “infinity” should be measured. A reading other the other test lead to one of the stator excitation wires than infinity indicates a winding (Figure 3.42).
  • Page 85 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments • Connect one meter test lead to a good ground. Connect the other test lead to the stator power winding (Figure 3.45). Figure 3.45 — Testing For Short To Ground A reading of infinity should be measured.

  • Page 86: Sincro® Wound" (Brushless Type Generators

    Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Figure 3.46 — Troubleshooting Flow Chart For “Sincro® Wound” (Brushless Type) Generators...

  • Page 87: Generators

    Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Troubleshooting Sincro® Wound • Run the engine for 10 seconds, then shut the engine OFF. Generators (Brushless Type) • Unplug the energizing cord from the generator Refer to Figure 3.46 receptacle and from the wall receptacle.
  • Page 88 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Test 4: — Testing Capacitor Figure 3.51 — Checking Excitation Resistance NOTE: Consult the owners manual of the meter you are using for capacitor test procedures. Test capacitor as shown in Figure 3.50 and compare with specifications found on capacitor.
  • Page 89 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments • Connect one test lead to an excitation wire. Connect Measure the resistance and compare it to the nominal the other test lead to a good metal ground resistance from the appropriate table (Figure 3.53).
  • Page 90 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments A reading of infinity should be measured. A reading of other •• Step 2: Testing Rotor Capacitor than infinity indicates a stator winding NOTE: Consult the owners manual of the meter Replace Stator shorted to ground .
  • Page 91 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments •• Step 3: Testing Rotor Diode NOTE: Consult the owners manual of the meter you are using for diode test procedures. Refer to Figure 3.58. Figure 3.58 — Testing Rotor Diode NOTE: If Diode, varistor or capacitor fails, and the winding is ok, replace the diode assembly.

  • Page 92: Voltage Regulator Adjustments

    Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments VOLTAGE REGULATOR ADJUSTMENTS To adjust the regulator, proceed as follows: • Slowly turn the voltage adjust pot (Figure 3.60) until “no-load” voltage is: Connect an (AC) voltmeter and frequency meter to panel electrical receptacles or to the stator (AC) power winding 115VAC (line-to-neutral) or leads.
  • Page 93 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments Units with power regulator and system control Although the voltage regulation process is “shared” by two boards circuit boards, the process is the same as when a one piece regulator is used.
  • Page 94 Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments...

  • Page 95: Generator Assemblies

    Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies DISASSEMBLY PROCEDURES General Recommendations For the most part, portable generators are heavy and Available Service Kits: awkward to work on. It is for that reason that basic safety Rotor Removal Kit Part # 41079 considerations must be incorporated into all handling and servicing procedures.

  • Page 96: Generac® Wound Generators

    Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies GENERAC® WOUND GENERATORS This exposes the components described in Generac Figure 4.1 — ® Wound Generator Figure 4.3. Figure 4.3 — Rear Bearing Carrier Exposed Excitation Wires Rotor Bearing Brush Assembly Disassembly They include:...
  • Page 97 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies Removing Brush Assembly Disconnecting Power Wires It is best to leave the DPE wires connected to the brush • Disengage the locks that secure the connector housing assembly during removal. to the plug on the back of the control panel (Figure 4.6).
  • Page 98 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies Remove Wire Terminals From Connector Housing • When all of the terminals are free of the housing, bend each of the locking tabs back to their original position There may be occasions where it is necessary to remove the as shown in Figure 4.9.
  • Page 99 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies Grounding Wire Figure 4.13 — Stator Bolts • Remove wing nut that secures the grounding wire to the cradle and save both of the locking star washers as shown in Figure 4.11. Figure 4.11 —...
  • Page 100 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies • Grip the stator and work it free from the engine Removing The Rotor adapter (Figure 4.15). The rotor is secured to a tapered shaft by means of a long through-bolt (Figure 4.17).
  • Page 101 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies Using the “Rotor Removal Kit,” proceed as follows: Figure 4.19 — Kit 41079 Components • Remove the rotor bolt and its washer (Figure 4.18). Figure 4.18 — Remove Rotor Bolt If the internal diameter of the rotor shaft is not threaded, select a tap from the kit as follows: If the rotor bolt diameter is1/4 inch:...
  • Page 102 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies • Carefully cut threads into the bearing end of the rotor • Insert and install the stud into the tapered shaft as shaft (Figure 4.20). shown in Figure 4.22. Figure 4.20 —...

  • Page 103: Assembly

    Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies • Remove rotor assembly (Figure 4.24) Figure 4.25 — Rotor In Housing Figure 4.24 — Remove Rotor Assembly Alignment Notch Rotor Bolt With Washer • Remove capscrew from rotor shaft. NOTE: Torque specifications can be found in the •...
  • Page 104 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies This notch aligns with a groove in the stator laminations Installing The Rear Bearing Carrier (Figure 4.27) that is approximately 1.5 inches long. The index mark on the rear bearing carrier consists of a “roll pin”...
  • Page 105 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies With the harness in the grommet: • Ensue that all the alignment marks are correct and seat the rear bearing carrier on the stator. • Carefully start the rotor bearing into the rear bearing carrier (Figure 4.31).
  • Page 106 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies • Install all the stator bolts by hand and only torque them Assembling The Wiring Harness to “finger tight.” • Install the protective mesh over the power wires as shown in Figure 4.36.
  • Page 107 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies The back of the connector plug has raised numbers that Reinstall Generator Ground Wire identify its specific compartments (Figure 4.38). Remove any supporting blocks that might still be holding the generator from resting in its cradle.
  • Page 108 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies Installing the Brush Assembly • Torque mounting screws (Figure 4.43) to specifications in the torque chart found in the appendix of this guide. Figure 4.41 shows the brush assembly with its terminal wires installed.
  • Page 109 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies • Install the lock washers and nuts to the vibration mount • Install the cover with the screws you retained from studs under the cradle frame arm disassembly. (Figure 4.45). •...
  • Page 110 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies...

  • Page 111: Sincro® Wound Generators

    Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies SINCRO® WOUND GENERATORS ® Removing Sincro® Access Cover DANGER: Before servicing any Sincro equipment, always remove the spark plug lead. • Remove the four screws holding the access cover to Unintentional ignition can cause severe personal the end of the sincro-generator (Figure 4.49).
  • Page 112 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies Before continuing with the disassembly process, visually Isolation Mounts inspect for the following: • Remove the two nuts that secure the isolation mounts to the cradle frame (Figure 4.52). •...
  • Page 113 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies • Disconnect the frame grounding wire (Figure 4.54). Figure 4.56 — Stator Housing Mounting Hardware Figure 4.54 — Disconnect Frame Grounding Wire Grounding Wire Mounting Nuts With the unit supported as described above: •...

  • Page 114: Assembly

    Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies • Continue tapping all the flanges on the housing until it Figure 4.59 — Rotor Bearing Snap-Ring comes free from the engine adapter. • Carefully remove the stator housing. Once the housing is removed, the rotor assembly will be exposed (Figure 4.58).
  • Page 115 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies • Secure the stator housing with the studs and nuts you • Reinstall the grounding wire as shown in retained from disassembly (Figure 4.61). Figure 4.63. Figure 4.61 — Secure Stator Housing Figure 4.63 —...
  • Page 116 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies Power Harness Cable • Reinstall capacitor and connect terminal ends as shown in Figure 4.67. • Reinstall the power harness cable connector as shown in Figure 4.65. Figure 4.67 — Install Capacitor Figure 4.65 —...
  • Page 117 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies...
  • Page 118 Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies...

  • Page 119: Generac® Torque Table

    Portable Generator Familiarization & Troubleshooting Guide Appendix A GENERAC® TORQUE TABLE...

  • Page 120: Generac® Receptacles And Plugs

    Portable Generator Familiarization & Troubleshooting Guide Appendix A GENERAC® RECEPTACLES AND PLUGS 22693 Receptacle 68868 74190 58889 58888 L5 - 30P 5 - 15P L5 - 20P 6 - 15P NEMA 93568 66883 26338 58890 Plug Part No. Volts Amps L5 - 30R 5 - 15R L5 - 20R...
  • Page 121 Portable Generator Familiarization & Troubleshooting Guide Appendix A GENERAC® RECEPTACLES AND PLUGS Receptacle 63025 68759 5 - 15P 5 - 20P NEMA 26338 Plug Part No. Volts Amps 5 - 15R DUPLEX 5 - 20R DUPLEX Configuration Receptacle 43629 66821 74191 6 - 50P 14 - 50P...

  • Page 122: Glossary

    Portable Generator Familiarization & Troubleshooting Guide Appendix A GLOSSARY ALTERNATING CURRENT (AC) CYCLE Current which varies in value from zero to a positive One complete reversal of alternating current of voltage, maximum and then back down through zero to a negative from zero to a positive maximum to zero to a negative maximum and back up to zero a number of times per maximum back to zero.The number of cycles per second is...
  • Page 123 Portable Generator Familiarization & Troubleshooting Guide Appendix A IDLE CONTROL RATED VOLTAGE A system which controls the idle speed of the engine in The rated voltage of an engine generator set is the voltage direct relation to the electrical load. at which it is designed to operate.
  • Page 124 Portable Generator Familiarization & Troubleshooting Guide Appendix A VIBRATION MOUNT A rubber device located between the engine or generator and the cradle to minimize vibration. VOLT The unit of elecro-motive force.That electromotive force which, when steadily applied to a conductor whose resistance is one ohm, will produce a current of one ampere.
  • Page 125 Portable Generator Familiarization & Troubleshooting Guide Appendix A...
  • Page 126 Portable Generator Familiarization & Troubleshooting Guide Appendix A...
  • Page 128 O O u u t t b b o o a a r r d d M M o o t t o o r r R R e e p p a a i i r r M M a a n n u u a a l l Visit u u s a a t: w w ww.briggsandstratton.com ® ® BRIGGS & STRATTON CORPORATION Milwaukee, WI 53201 Part No. 86262GS 9/05 Quality Starts With A Printed in U.S.A. Master Service Technician...

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