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Briggs & Stratton Powersmart 30473 Service And Repair Manual

Powersmart series inverter generator
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POWERSMART SERIES™ INVERTER GENERATOR
SERVICE AND REPAIR MANUAL
MODEL 030473
This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2
No. 100-04 (motors and generators)
279957GS Rev. -

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Summary of Contents for Briggs & Stratton Powersmart 30473

  • Page 1 POWERSMART SERIES™ INVERTER GENERATOR SERVICE AND REPAIR MANUAL MODEL 030473 This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators) 279957GS Rev. -...
  • Page 2 Briggs & Stratton Power Products Group, LLC P.O. Box 702 Milwaukee, WI 53201-0702 Copyright © 2010. All rights reserved. No part of this material may be reproduced or transmitted in any form without the express written permission of Briggs & Stratton Power Products Group, LLC. BRIGGSandSTRATTON.COM...

  • Page 3: Table Of Contents

    Table of Contents Important Safety Instructions......4 Generator Components ......9 Maintenance .

  • Page 4: Important Safety Instructions

    Important Safety Instructions SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. Safety Symbols and Meanings Toxic Fumes Kickback Electrical Shock Fire Explosion Read Manual WARNING Running engine gives off carbon monoxide, an odorless, colorless, poison gas.
  • Page 5 WARNING Generator voltage could cause electrical WARNING Fuel and its vapors are extremely flammable shock or burn resulting in death or serious injury. and explosive which could cause burns, Use approved transfer equipment to prevent fire, or explosion resulting in death, serious backfeed bt isolating generator from electric utility injury, and/or property damage.
  • Page 6 NOTICE  Exceeding generators wattage/amperage WARNING Unintentional sparking could cause fire or capacity could damage generator and/or electrical devices electric shock resulting in death or serious connected to it. injury. • DO NOT exceed the generator’s wattage/amperage capacity. See Don’t Overload Generator in the Operator’s When Adjusting Or Making Repairs To Your Generator Manual.
  • Page 7 Fuel Recommendations Generator Location Fuel must meet these requirements: WARNING Exhaust heat/gases could ignite combustibles • Clean. fresh, unleaded gasoline or structures resulting in death, serious injury and/or property damage. • A minimum of 87 octane/87 AKI (91 RON) • Gasoline with up to 10% ethanol (gasohol) or up to 15%MTBE (methyl tertiary butyl ether) is acceptable.
  • Page 8 Fuel Tank Cap Vent Lever Grounding Fastener The fuel tank cap is provided with a vent lever (A, Figure 2) to The generator neutral is floating, which means that the AC seal the fuel tank. The vent lever must be in the “ON” position stator winding is isolated from the grounding fastener and for the engine to run.

  • Page 9: Generator Components

    Generator Components A - Fuel Tank Cap Vent Lever — Turn the vent lever to the L - Overload Alarm — A red LED light comes on and “ON” position when operating the generator. Turn to the cuts power to the receptacles when the generator is “OFF”...

  • Page 10: Maintenance

    Maintenance Generator Maintenance Generator maintenance consists of keeping the unit clean Maintenance Schedule and dry. Operate and store the unit in a clean and dry Follow the hourly or calendar interval, whichever occurs first. environment where it will not be exposed to excessive dust, More frequent service is required when operating in adverse dirt, moisture, or any corrosive vapors.

  • Page 11: Engine Maintenance

    Engine Maintenance Checking Oil Level / Adding Oil WARNING Unintentional sparking could cause fire or Oil level should be checked prior to each use or at least every electric shock resulting in death or serious 8 hours of operation. Keep oil level maintained. injury.
  • Page 12 Changing Engine Oil Service Air Cleaner If the generator is used under extremely dirty or dusty The engine will not run properly and may be damaged if it is conditions, or in extremely hot weather, change the oil more run with a dirty air cleaner. Service more often if operating often.
  • Page 13 Service Spark Plug 4. Remove spark plug and inspect for pitting, corosion, cracks, or other signs of damage. 1. Loosen the four handle screws and remove the handle (Figure 8). Check electrode gap with wire feeler gauge (A, Figure 10) and reset the spark plug gap to recommended gap if necessary.
  • Page 14 Inspect Muffler and Spark Arrester 2. Remove screw (Figure 12) that attaches spark arrester screen muffler. Remove spark arrester screen. Inspect the muffler for cracks, corrosion, or other damage. Remove the spark arrester, if equipped, and inspect for damage or carbon blockage. WARNING Exhaust heat/gases could ignite combustibles or structures resulting in death, serious injury and/or property damage.

  • Page 15: Rewind Starter Replacement

    Rewind Starter Replacement 4. Pull out rope from rewind starter as far as it will go. Disassemble Rewind Starter Then allow rope to retract slightly until the hole in the 1. Remove control panel, inverter, and fuel tank as pulley and eyelet in the housing are lined up. Securely described in the Troubleshooting section.
  • Page 16 Figure 15 Assemble Rewind Starter Inspect Rewind Starter Parts 1. Install pulley and spring assembly into starter housing. 1. Inspect the pulley for wear, cracks, rough edges, or Rotate pulley clockwise until slight resistance is felt, burrs in the rope groove and look for wear in the center which indicates that the spring has engaged in the hole.

  • Page 17: Troubleshooting

    Troubleshooting Fuel Tank Fuel System The fuel tank is metal (A, Figure 17) and is not repairable. Fuel Pump Inspect tank for: The fuel pump (A, Figure 16) is located on inside of cover. • Corrosion It is operated by vacuum pulses from the engine. The fuel •...
  • Page 18 Fuel Valve Check the fuel valve for leaks (C, Figure 21). The fuel valve is mounted behind the side maintenance cover. Check the valve for proper operation as follows: 1. Using small, flat-head screwdriver, pry off cover to the fuel valve knob (Figure 19). Figure 21 If the fuel valve leaks, it must be replaced as follows: Loosen four screws (Figure 22) on the control panel.
  • Page 19 Remove control panel from enclosure and, without 5. Locate fuel valve (F, Figure 25) inside of the generator disconnecting wiring, set control panel aside (D, Figure 23). enclosure. 3. Remove inverter from enclosure (E) and, without Remove hoses (G) and loosen screw (H) to remove the disconnecting wiring, set inverter assembly aside.
  • Page 20 Carburetor 3. Remove screw from air filter cover (Figure 28). Set cover aside. Inspect carburetor for: • Blockage • Leaks • Varnish or Gummy Residue If carburetor is suspected to have a fuel leak or blockage, follow these steps: 1. Loosen the two self-locking screws and remove the side maintenance cover (Figure 26) and set aside.
  • Page 21 8. While leaving the stepper motor attached, carefully slide 5. Remove air cleaner assembly and set aside (Figure 30). carburetor assembly off engine. 9. Remove bowl nut (Figure 33) and the fuel bowl. Check for damage, leaks, and gummy residue. Figure 30 Figure 33 6.
  • Page 22 11. Ensure the inlet needle and spring (A) are assembled 14. Inspect openings in the carburetor body for blockage. correctly, with the spring located below the float bosses Inspect throttle and choke shafts for wear or damage. If (Figure 35). found, replace the entire carburetor assembly.

  • Page 23: Stepper Motor

    Stepper Motor The stepper motor (electric throttle actuator) responds to the 2. Measure the resistance across wires (B, Figure 39). inverter module to continuously match engine speed to the 3. Measure the resistance across wires (C, Figure 39). power needs of the generator. Resistance should measure between 45 - 55 Ω.
  • Page 24 2. Remove two screws that hold the stepper motor to the 4. Actuate the throttle lever to check for proper movement carburetor assembly (F, Figure 41). (Figure 42). The lever should move freely in both directions. 3. Locate the throttle lever (G). 5.

  • Page 25: Engine Will Not Start

    Engine Will Not Start The Engine Cranks But Has No Spark 3. Turn the microswitch on and test between the terminal (A, Figure 45) and ground. If the engine cranks but has no spark, it could be the micro switch (A, Figure 43). Figure 45 Figure 43 •...
  • Page 26 Low Oil Switch 4. Test for continuity between ground and the low oil switch (A, Figure 49). The low oil indicator system is designed to prevent engine damage caused from insufficient engine oil. If the engine • If continuity is not measured, the switch is good. oil level drops below a preset level, the yellow LED low oil •...
  • Page 27 Ignition Spark Circuit 4. Disconnect ignition winding. When the engine is running the 27V coil produces a voltage 5. Measure the resistance at the terminal (A, Figure 52). that is present at the ignition module. When the magnet on the flywheel (rotor) passes by the trigger coil, this trigger voltage is sensed by the ignition module.
  • Page 28 3. Measure the resistance between the trigger coil Test Ignition Coil (A, Figure 54) and ground. 1. Locate the connector for the ignition coil (A, Figure 56) and disconnect.. Figure 54 Figure 56 • If 80-130 Ω resistance is measured the coil is good. •...

  • Page 29: No Ac Output

    Ignition Module 3. Attach one test lead to either terminal of ignition coil connector and the other lead to the spark plug cap There is no test for the ignition module. If all ignition winding (Figure 58) to measure the secondary resistance. tests are correct, the ignition module is faulty.

  • Page 30: No Dc Output

    Then measure resistance across sub-windings (E, Figure 64). 3. Measure for 120 VAC ouput (C, Figure 62). Figure 62 Figure 64 • If voltage is not measured, check for loose wiring. • If resistance is 0.15 - 0.30 Ω the windings are good. •...
  • Page 31 3. Locate battery winding connector (B, Figure 67) and 2. Disassemble panel cover to locate and check the wire mesure resistance across the terminals (C). connections (A, Figure 66). Figure 66 • Repair and/or replace any loose wire connections and retest.

  • Page 32: Generator Specifications

    Generator Specifications Starting Wattage 2,000 Watts Wattage* 1,600 Watts Load Current at 120 Volts AC 13.3 Amps at 12 Volts DC 5 Amps Rated Frequency 60 Hertz Phase Single Phase Displacement 6.44 cu. in. (105.6 cc) Spark Plug Gap .025 in. (.65 mm) Intake Valve Clearance .003 - .005 in.

  • Page 33: Generator Wiring Diagram

    Generator Wiring Diagram...

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