190275GS Hand Held Generators

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HAND-HELD GENERATOR
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www.briggspowerproducts.com
TM
BRIGGS & STRATTON CORPORATION

Quality Starts With A Milwaukee, WI 53201
Part No. 190275-5/03 Printed in U.S.A.
Master Service Technician
www.mymowerparts.com
FOREWORD
This guide has been written and published by Briggs & Stratton Corporation to aid our dealers’ mechanics and
company service personnel when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar
products, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in the
recommended servicing procedures for these products, which includes the use of mechanics’ hand tools and any
special tools that might be required.
Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems.
The troubleshooting, testing, service and repair procedures described in this guide are effective methods of
performing such operations.
We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a
service might be performed, nor of any possible hazards and/or results of each procedure or method.We have not
undertaken any such wide evaluation.Therefore, anyone who uses a procedure or method not described by the
manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be endangered by
the service or operating procedure selected.
All information, illustrations, and specifications contained in this guide are based on the latest production
information available at the time of publication. However, Briggs & Stratton Corporation reserves the right to
change, alter, or otherwise improve the product at any time without prior notice.
Some components or assemblies of the product described in this guide may not be considered repairable.
Disassembly, repair and reassembly of such components may not be included in this guide.
Copyright © 2003 Briggs & Stratton Corporation
All rights reserved.
No part of this material may be reproduced or transmitted, in any form or by any means, electronic or
mechanical, including photocopying, recording or by any information storage and retrieval system, without prior
permission in writing from Briggs & Stratton Corporation.
Please click the “Bookmarks” tab at left to enable the
search and navigational features of this document.
®
Electronic Version #190275 03/03
Hand-Held Series Generator

Familiarization & Troubleshooting Guide
FORWARD
This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and
company service personnel when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar
products, manufactured by Briggs & Stratton Power Products Group®. It is also assumed that they have been
trained in the recommended servicing procedures for these products, which includes the use of mechanics hand
tools and any special tools that might be required.
Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems.
The troubleshooting, testing, service and repair procedures described in this guide are effective methods of
performing such operations.
We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a
service might be performed, nor of any possible hazards and/or results of each procedure or method. We have
not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by
the manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be
endangered by the service or operating procedure selected.
All information, illustrations, and specifications contained in this guide are based on the latest production
information available at the time of publication. However, Briggs & Stratton Corporation reserves the right to
change, alter, or otherwise improve the product at any time without prior notice.
Some components or assemblies of the product described in this guide may not be considered repairable.
Disassembly, repair and reassembly of such components may not be included in this guide.
Service and repair instructions for the engines used to power these products are not covered in this guide.
Engine service and repair instructions are furnished by the engine manufacturer.
Copyright © 2003 Briggs & Stratton Corporation
All rights reserved.
No part of this material may be reproduced or transmitted, in any form or by any means, electronic or
mechanical, including photocopying, recording or by any information storage and retrieval system, without prior
permission in writing from Briggs & Stratton Corporation.
Hand-Held Series Generators • Familiarization & Troubleshooting Guide
Tabe of Contents
TABLE OF CONTENTS
1 INTRODUCTION 3 TROUBLESHOOTING
In The Interest of Safety

Safety Alert Symbols
4
4
Under-Voltage (DC)
Check (DC) Circuit Breaker
22
23
1
Safety Practices 5 Check Bridge Diode 23
Generator Description 8 Check 12VDC Coil 23
Generator Components 9 Over-Voltage (AC) 24
Serial Number Locations 10 Check Capacitor 24
2
Generator Specifications 10 Under-Voltage (AC) 26
Wiring Diagram 11 Check Receptacle Wiring 27
Output Power (AC) 11 Check (AC) Circuit Breaker 27
Output Power (DC) 11 Check Stator Power Winding 28
Fuel System Components 12 Check Excitation Winding 28
Fuel Group 12 Check Rotor Winding 29
General Service Information 12 Engine Switch 29
3
Work Area 12 Pilot Lamp 30
Hand Tools 12
Special Tools 12 4 ASSEMBLY
2 DISASSEMBLY
Mounting The Rotor & Stator 33
General Disassembly Considerations 15 Installing The Muffler Heat Shield 34
Case Separation 15 Connecting The Wiring Harness 35
Mount The Rear Case Half 36
4
Access To Generator Components 17
Rotor / Stator Removal 18 Mount The Fuel Tank 37
Mount The Front Case Half 37
5 APPENDIX
Resistance Values 43
Torque Specifications 43
Fasteners and Locations 44
5
1
Table of Contents
5
2
Section 1 • Introduction
INTRODUCTION 1
3
Introduction • Section 1
INTRODUCTION
In the Interest of Safety CAUTION: Indicates a hazard
1
DANGER
which, if not avoided might
This manual outlines the construction, result in death or serious Generator produces
function and servicing procedures of injury. powerful voltage.
the Briggs & Stratton Power Products® Failure to isolate generator
“Hand-Held” generator series. It is from power utility can result
CAUTION: When used without the
structured for use by trained in death or injury to electric
alert symbol, indicates a situation that
technicians that are working in a could result in damage to equipment. utility workers due to
properly equipped shop. Familiarity backfeed of electrical energy.
with the proper method of using tools, • When using generator for backup
measuring equipment and workshop NOTE: This notation is used to power, notify utility company. Use
procedures are essential to performing inform you of a method, reference approved transfer equipment to isolate
successful maintenance and repair on or procedure that could assist with generator from electric utility.
this equipment. specific operations or decisions. • Use a ground circuit fault interrupter
(GFCI) in any damp or highly
Ensure that all specified tools and/or
HAZARD SYMBOLS AND MEANINGS conductive area, such as metal decking
equipment are available before or steel work.
attempting to service this equipment.
• Do not touch bare wires or
For a detailed discussion of the receptacles.
fundamental principles involved with • Do not use generator with electrical
the physics of electrical power cords which are worn, frayed, bare or
Toxic Fumes Electrocution Explosion
generation, refer to the "Familiarization otherwise damaged.
and Troubleshooting Guide • Do not operate generator in the rain.
(Publication #86262 Revision 3 or
• Do not handle generator or electrical
later)". This manual is available
cords while standing in water, while
through your Briggs & Stratton Central Hot Surface Chemical Burns Fire
barefoot, or while hands or feet are
Distributor. wet.
Safety Alert Symbols • Do not allow unqualified persons or
The safety alert symbol ( ) is used children to operate or service
Read Explosive Pressure Goggles generator.
to identify safety information about
hazards that can result in personal
injury. A signal word (DANGER, DANGER
WARNING, CAUTION) is used Running generator gives off
Kick Back Disconnect Entanglement carbon monoxide, an
with the alert symbol to indicate the
Spark Plug
potential severity of injury. In addition, odorless, colorless, poison
a hazard symbol may be used to gas.
represent the type of hazard. Breathing carbon monoxide
DANGER will cause nausea, fainting or
Failure to properly ground death.
DANGER: Indicates a hazard generator can result in
• Operate generator ONLY outdoors.
which, if not avoided will result electrocution, especially if the
in death or serious injury. generator is equipped with a • Keep at least 2 feet of clearance on all
wheel kit. sides of generator for adequate
ventilation.
• National electric code requires
WARNING: Indicates a hazard generator to be properly grounded to • Do not operate generator inside any
which, if not avoided could an approved earth ground. Call an building or enclosure, including the
result in death or serious electrician for local grounding generator compartment of a
injury. requirements. recreational vehicle (RV).
4
DANGER WARNING Safety Practices

Storage batteries give off
explosive hydrogen gas Fuel and its vapors are • Generator exhaust gases contain
during recharging. extremely flammable and DEADLY carbon monoxide gas.
explosive. This dangerous gas, if breathed
Hydrogen gas stays around
battery for a long time after Fire or explosion can cause in sufficient concentrations, can
battery has been charged. severe burns or death. cause unconsciousness or even
Slightest spark will ignite death. Operate and service this
hydrogen and cause WHEN ADDING FUEL equipment only in the open air
explosion. • Turn generator OFF and let it cool at where adequate ventilation is
You can be blinded or least 2 minutes before removing gas available.
severely injured. cap. Loosen cap slowly to relieve • These generators were designed
pressure in tank.
Battery electrolyte fluid and manufactured for
contains acid and is • Fill fuel tank outdoors. recreational applications. Do not
extremely caustic. • Do not overfill tank. Allow space for attempt to modify the unit or
Contact with battery fluid fuel expansion. use it for any application it was
will cause severe chemical • Keep all fuel away from sparks, open not designed for. If you have any
burns. flames, pilot lights, heat, and other questions about your generator's
• Do not allow any open flame, spark, ignition sources. application, ask your dealer or
heat, or lit cigarette around battery • Do not light a cigarette or smoke. consult the factory.
during, and for several minutes after
charging. WHEN OPERATING EQUIPMENT • The manufacturer could not
• Do not tip engine or equipment at possibly anticipate every
• Wear protective goggles, rubber
angle which causes fuel to spill. circumstance that might involve a
apron, and rubber gloves.
WHEN TRANSPORTING OR hazard. For that reason, warnings
REPAIRING EQUIPMENT in manuals and warnings on tags
DANGER or decals affixed to the units are
• Transport/repair with fuel tank EMPTY
Running engines produce or with fuel shutoff valve OFF. not all-inclusive. If you intend to
heat. Temperature of muffler handle, operate or service a unit
• Disconnect spark plug wire.
and nearby areas can reach with a procedure or method not
or exceed 150°F (65°C). • Do Not operate generator in a moving specifically recommended by the
vehicle or watercraft, because motion
Severe burns can occur on manufacturer, make sure that
can cause fuel to spill.
contact. such a procedure or method will
WHEN STORING FUEL OR not render the equipment unsafe
• Do not touch hot surfaces.
EQUIPMENT WITH FUEL IN
• Allow equipment to cool before or pose a threat to you and
TANK
touching. others.
• Store away from furnaces, stoves,
water heaters, clothes dryer or other • Read these procedures carefully
WARNING appliances that have pilot light or other and become familiar with your
ignition source because they can ignite generator set. Know its
• This generator does not meet U.S.
fuel vapors. applications, its limitations and
Coast Guard Regulation 33CFR-183 and
should not be used on marine any hazards involved.
applications.
WARNING
• Failure to use the appropriate U.S.
Coast Guard approved generator could The engine exhaust from this product
result in bodily injury and/or property contains chemicals known to the State of
damage. California to cause cancer, birth defects,
or other reproductive harm.
5
• Hand-held generators produce a very powerful

voltage that can cause an extremely dangerous
electrical shock. Avoid contact with bare wires,
terminals, etc. Never permit an untrained person to
service or assist with the procedures discussed in this
guide.
• Never handle any kind of electrical cord or device
while standing in water, while barefoot, or while
hands or feet are wet.
• Do not use worn, bare, frayed or otherwise damaged
electrical cord sets with any generator set. Using a
defective cord may result in an electrical shock or
damage to the test equipment and/or the unit.
• Gasoline is highly flammable and its vapors are
EXPLOSIVE. Do not permit smoking, open flames,
sparks or heat in the vicinity while handling gasoline.
Avoid spilling gasoline on a hot engine. Comply with
all laws regulating storage and handling of gasoline.
• Do not overfill the fuel tank. Always allow room for fuel
expansion. If the tanks are over-filled, fuel can overflow on
`to a hot engine and cause FIRE or EXPLOSION.
• These units require an adequate flow of cooling air for their
continued proper operation. Never operate or service any
unit while inside any enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Without sufficient cooling airflow, the units quickly
overheat, damaging the generator and/or nearby property.
• Never start or stop a unit with electrical loads connected
to receptacles and with the connected loads turned ON.
Start the engine and let it stabilize before connecting any
electrical loads. Turn OFF and disconnect all electrical
loads before shutting down any generator.
• This entire book is filled with important safety information
- please read it carefully.
6
7
GENERATOR DESCRIPTION
1
Figure 1 — Internal Components
9 10 11 12 13
14
15
7
6 16
17
5
4 18
3
2 19
1
20
Item Nomenclature Item Nomenclature
1. Vibration Mount 11. Fuel Inlet Filter

2. Bearing Carrier 12. Spark Plug
3. Cooling Fan 13. Generator Case Half
4. Rotor Bearing 14. Fuel Filter
5. Rotor Bolt (M6-160) 15. Fuel Hose
6. Rotor Assembly 16. Fuel Valve
7. Stator Bolt (M6-90) 17. Air Cleaner
8. Stator Assembly 18. Carburetor
9. Fuel Tank 19. Engine
10. Fuel Cap 20. Engine Base
8
GENERATOR COMPONENTS
1
Figure 2 — External Components
Recoil Starter Fuel Cap
Engine Switch
Fuel Shut-Off
Choke Lever
Control Panel
Oil Service Cover
Grounding Lug
Air Cleaner
Data Plate Recoil Starter
Muffler
Spark Plug Access

Cooling Fan
9
Serial Number Locations Generator Specifications
1 Figure 3 — Engine Serial Number Location Engine:

Name:
Type:
GM82 or Vanguard
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
Figure 4 — Generator Serial Number Location (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
10
GENERATOR SYSTEMS
1
Figure 5 — Generator Wiring Diagram
Output Power (AC) power and excitation windings until magnetic saturation and
condenser capacity is balanced. This is the calculated "Rated
The residual magnetism of the rotor induces an (AC)
Output" of the generator.
voltage in the power and excitation windings when the rotor
is turned by hand (when recoil starter is pulled). The (AC) When an external load is plugged into an output receptacle,
voltage of the excitation winding builds in the condenser the increased current flow intensifies the magnetic field of
until it discharges. This "capacitive discharge" then the power winding. As the magnetic field of the rotor "cuts"
strengthens the magnetic field in the excitation winding. As across the intensified field of the power winding, an
the rotor windings "cut" this strengthened magnetic field, a additional voltage is induced into the rotor field winding.
higher (AC) voltage is induced in the rotor winding. The This increases the output of the power winding to
diode in the rotor rectifies the induced rotor (AC) to (DC). compensate for the voltage drop of the load.
The intensified magnetic field of the rotor "cuts" across both
the power and excitation windings. When the engine starts Output Power (DC)
and spins the rotor, residual magnetism is overcome and this (AC) voltages that are induced into the 12VAC winding are
cycle continues to increase the (AC) output voltage of the rectified to (DC) by a "full-wave" bridge rectifier.
11
Fuel System Components GENERAL SERVICE INFORMATION
1 Fuel Group:
The components that make up the Fuel group include the
items listed in Figure 6.
Work Area
Good lighting and an elevated table will help you gain access
to all of the mounting hardware and accessories of the hand-
Figure 6 — Fuel Systems Components
held generator. Certainly, larger is better but a good
Shut-Off Valve Fuel Cap Assembly
minimum sized table would be 20in. by 30in. If casters are
applied to the legs of the table, be sure they are secure and
sturdy enough to support not only the generator but also
Tank Sump Filter the work being performed.
Fuel Hose
Fuel Strainer
Spill Well Hand Tools

A minimum collection of standard mechanic's hand tools
should include:
· 3/8" drive socket set (SAE)
· 3/8" drive socket set (Metric)
Mounting Brackets · A 3/8" drive ratchet
Tank
· Short, medium and long 3/8" drive extensions
· A large (heavy) "soft" mallet
The items listed in Figure 7 are part of the fuel cap and are · A common screwdriver (medium length)
not replaceable. If damage occurs to the fuel cap, its repair is · A Phillips screwdriver (medium length)
limited to replacement.
· A Phillips screwdriver (short- "stubby")
Figure 7 — Fuel Cap Assembly · A large (heavy duty) screwdriver suitable for mild prying
Special Tools
Electronic Measuring Equipment:
The measuring equipment used in troubleshooting should be
of industrial quality and have the sensitivity to measure
electronic values to the third decimal. Its accuracy should be
within acceptable tolerances should have the ability to
measure capacitance.
12
Section 2 • Disassembly
DISASSEMBLY 2
13
Disassembly • Section 2
14
General Disassembly Considerations NOTE: Do not attempt to remove the protective

grill that surrounds the exhaust muffler. The fasteners
Always inspect the external condition of the plastic
that hold it in place are secured with plain nuts and
components before disassembling the unit. Look for cracks
lock-washers. If you attempt to remove the grill, it
and broken plastic and be sure to note these conditions as
will be necessary to disassemble the case halves in
existing before maintenance is undertaken.
order to reinstall it properly.
Hand-held generators are built to close tolerances. The Case Separation

fasteners used to hold the plastic shrouds and covers are
• Remove the cover to the air cleaner.
special machine screws that have a "pilot" collar
incorporated into the grip area of the screw (Figure 8). • Set the air filter and support grill aside.
Figure 8 — Screws with ”Pilot Collar”

• Remove the two mounting nuts that hold the air filter
assembly to the carburetor (Figure 48, Pg. 34).
• Remove the two screws that hold the handle of the
unit together (Figure 9).
2
Figure 9 — Remove Screws In Handle
Pilot Collars
NOTE: When assembling plastic components, be

sure the "collar" of the screw fits into the opening of
the shroud or cover. Pinching the plastic under the
collar will break the plastic at the mounting locations.
The length of these fasteners is critical to the proper
assembly of the unit. When disassembling the generator, it is At this point, position the unit so you are facing the muffler
recommended that the location and length of each fastener side of the generator.
be noted.
• Remove only those fasteners that hold the rear case
half. That is:
When troubleshooting becomes necessary, access to various • Those screws around the lower base of the rear
components, systems and structural members is required. of the generator.
Regardless of the ultimate reason, a clear understanding of
• The upper screws that secure the rear case-half
the unit's disassembly will save time and effort.
on the right and left side of the generator.
• Grasp the rear case half and gently separate it from the
generator unit.
15
• Remove the screw that is next to the fuel shut-off valve

and retain the mounting bracket that supports the fuel
tank (Figure 10).
Figure 10 — Mounting Bracket Screw
2
• Slide the fuel tank out of its cradle and remove the fuel
supply hose from the bottom of the tank (Figure 11).
Figure 11 — Remove Fuel Supply Hose
Hose to Tank
16
ACCESS TO GENERATOR COMPONENTS
Figure 12 — Access To Generator Components
NOTE: At this point, you have visual access to • Position the unit so you are facing the front of the
many of the mechanical and electronic components of generator.
the generator (Figure 12). • Remove the screws around the base.
Many individual electronic components are supported by • Separate the electrical connectors at locations shown in
clips and brackets that are molded parts of the front case Figures 13A and 13B.
half. This disassembly procedure assumes you are seeking • Set the front case-half aside.
access to the engine and generator for overhaul purposes
and the components that are held by the case will be left in
their mountings.
Figure 13 — Generator Components
A Harness Connectors B
17
This provides sufficient access to the generator unit for Rotor / Stator Removal
troubleshooting, component replacement and overhaul
(Figure 14). •• Step 1:
• For easier access, position the unit as shown in
figure 16.
Figure 14 — Generator Unit Exposed
Figure 16 — Position For Rotor Removal / Inspection
A view of the electrical components that are mounted on

the inside of the front case-half is provided in Figure 15. •• Step 2:
Remove the cooling fan as shown. (Figure 17).
Figure 15 — Electrical Components Mounted On Case Figure 17 — Remove Cooling Fan
NOTE: Mark the face of the fan to ensure proper

reassembly.
18
•• Step 3: •• Step 6:
• Remove the heat shield mounting screws (Figure 18A). • Remove the rear bearing carrier and the stator
together (Figure 20).
•• Step 4: Figure 20 — Remove Stator Housing & Stator

• Remove the rear bearing carrier mount bolts
(Figure 18B).
Figure 18 — Hardware (Heat Shield / Stator Housing)
A B
•• Step 5:
• Remove the three through-bolts (Figure 19).
Figure 19 — Remove Stator Through-Bolts
19
20
Section 3 • Troubleshooting
TROUBLESHOOTING 3
21
Troubleshooting • Section 3
Figure 21 — Under-Voltage (DC) Troubleshooting Flow Chart
Test A
Check Engine RPM Repair/Replace DC
OK? NO YES
See Appendix See B&S #272147 OK?
YES NO
Test B Repair/Replace
OK? NO DC YES
Check See Page 25 OK?
Receptacle
Wiring
YES NO
Test C Repair/Replace
OK? DC
Check DC NO
See Page 21 OK?
YES END
Circuit
Breaker
3 YES NO
Test D Repair/Replace
OK? NO DC YES
Check Bridge See Page 21 OK?
Diode
YES NO
Test E Repair/Replace
OK? NO DC YES
Check 12VDC See Page 21 OK?
Coil
YES NO
Test F Repair/Replace
OK? NO DC YES
Check Rotor See Page 27 OK?
Winding
YES NO
Under Voltage (DC) Test A: - Check Engine RPM

Refer to Figure 21 ("Under Voltage (DC)" Flow Chart) (See Appendix)
above for the sequential steps involved with this procedure.
To separate the case halves, see page 13.
Test B: - Check Receptacle Wiring
(Page 25)
22
Test C: - Check (DC) Circuit Breaker

Figure 23 — Checking The Bridge Diode
•• Step 1:
• Remove the three screws that secure the control panel
to the face of the generator unit.
•• Step 2:
• Remove both the terminals at the back of the circuit
breaker (Figure 22A). Negative Probe (-)
Positive Probe (+)

•• Step 3: (+) ~1 ~2 (-)
• With the circuit breaker ON and your VOM set to (+) Yes Yes Yes
ohms, check for continuity at the terminals of the ~1 No No Yes
circuit breaker (Figure 22B). ~2 No No Yes
Figure 22 — Checking (DC) Circuit Breaker
(-) No No No
Test E: - Check 12VDC Coil
With the control panel still removed:
•• Step 1:
• Locate and separate the harness connector that has the
3
two brown wires coming.from the stator.
•• Step 2:
A B • With your VOM set to ohms, read the coil resistance
at the terminal of the brown leads in the connector
- Continuity = Circuit Breaker OK (Figure 24).
- No Continuity = Defective Circuit Breaker.
Figure 24 — Reading 12VDC Coil Resistance
Replace Circuit Breaker
Test D: - Check Bridge Diode
With the control panel still removed: Brown
•• Step 1:
• Locate and separate the harness connector that has the
two brown wires. Push the male half of the connector
aside.
NOTE: You must follow the Diode Test

instructions that are provided with the meter you are
using.
•• Step 2:
• Using the female terminals of the brown wires and the
positive output terminal of the cigarette lighter, or the •• Step 3:
DC receptacle, you can check continuity of the bridge • Compare readings with resistance values in the
diode wiring (Figure 23). apppendix.
Test F: - Check Rotor Winding
(See Test G on Page 27)
23
Figure 25 — Over-Voltage (AC) Troubleshooting Flow Chart
Test A Test B
Check Engine RPM OK? YES Check OK? NO Repair/Replace
See Appendix Capacitor See Page 22
NO YES
NO
Repair/Replace AC
See B&S #272147 OK?
YES END AC
YES
OK?
NO
"Over Voltage" (AC)

Figure 26 — Remove Control Panel
3
Refer to Figure 25 ("Over Voltage (AC)" Flow Chart) above
for the sequential steps involved with this procedure. To
separate the case halves, see page 13.
Test A: - Check Engine RPM

(See Appendix)
Test B: - Check Capacitor
The capacitor can be checked without disassembling the unit

case-halves.
•• Step 1:
to the face of the generator unit (Figure 26).
•• Step 2:
• Disconnect the harness connector that has the two
yellow wires.
•• Step 3:
• Using a jumper wire, (Figure 27) short the two yellow
terminals that come from the capacitor. Then remove
the jumper wire.
24
Figure 27 — Short the Capacitor Terminals
Yellow
•• Step 4:
• Refer to the owner's manual of your VOM and test the
3
capacitor according to the directions for your
equipment.
Figure 28 — Testing the Capcitor
• Find the rating of the capacitor on its body or in the

appendix of this manual.
• Compare reading with the stated value .
Replace the capacitor if it is found to be faulty.
25
Figure 29 — Under-Voltage (AC) Troubleshooting Flow Chart
Test A Repair/Replace
OK? NO AC YES
Check Engine RPM See B&S #272147 OK?
See Appendix
YES NO
Test B Repair/Replace
OK? NO AC YES
Receptacle
Wiring
YES NO
Test C Repair/Replace
OK? AC
Check AC NO
See Page 25 OK?
YES END
Circuit
Breaker
3
YES NO
Test D Repair/Replace
OK? NO AC YES
Check Stator See Page 26 OK?
Power
Winding
YES NO
Test E Repair/Replace
OK? NO AC YES
Capacitor
YES NO
Test F Repair/Replace
OK? NO AC YES
Excitation
Winding
YES NO
Test G Repair/Replace
OK? NO AC YES
Check Rotor See Page 27 OK?
Winding
YES NO
26
Under Voltage (AC) Test C: - Check AC Circuit Breaker

Refer to Figure 29 ("Under Voltage (AC)" Flow Chart) on
the preceding page for the sequential steps involved with
•• Step 1:
this procedure. To separate the case halves, see page 13.
Remove both the terminals at the back of the circuit
breaker (Figure 31A).
Test A: - Check Engine RPM
(See Appendix)
•• Step 2:
• With the circuit breaker CLOSED and your VOM set
Test B: - Check Receptacle Wiring to ohms, check for continuity at the terminals of the
circuit breaker (Figure 31B).
•• Step 1: Figure 31 — Checking Circuit Breaker

•• Step 2:
• Test the receptacle for:
- Shorted contacts.
- Burned or cracked insulation material.
- Faulty terminal screws (Figure 30).
- Continuity: = Circuit Breaker - OK
3
Figure 30 — AC Receptacle
- No Continuity: = Defective Circuit Breaker.
Replace Circuit Breaker
•• Step 3:
• If any faults are found,
- Replace receptacle.
27
Test D: - Check Stator Power Winding Test F: - Check Excitation Winding
•• Step 1: •• Step 1:
• Disconnect the 4-pin harness connector that contains • Disconnect the harness connector that contains the
the yellow wires. yellow wires.
•• Step 2: •• Step 2:
• On the male portion of the connector, locate the pins • On the male portion of the connector, find the pins
that connect the blue and red wires (This harness that connect the two yellow wires (This harness should
should be coming from the generator stator assembly be coming from the generator stator assembly see
see figure 32). figure 33).
•• Step 3: •• Step 3:
• With your VOM set to ohms, measure the resistance • With your VOM set to ohms, measure the resistance
across the blue and red wires that come from the across the two yellow wires that come from the stator
stator (Figure 32). (Figure 33).
3
Figure 32 — Checking Stator Power Winding Figure 33 — Checking Excitation Winding
• Compare reading with the resistance values in the • Compare reading with the resistance values in the
appendix. appendix.
- Within tolerance: Power winding is good - Within tolerance: Excitation winding is good
- Exceeds tolerance: Replace Stator - Exceeds tolerance: Replace Stator
Test E: - Check Capacitor

(Page 22)
28
Test G: - Check Rotor Winding Engine Switch

•• Step 1:
The rotor is considered a non-serviceable part because it is
a sealed unit that would require disassembly to properly
test. Therefore, it is by process of eliminating all other
possible faults that the rotor can be considered faulty. •• Step 2:
• Remove the terminals from the switch.
NOTE: Piercing the red or blue wire and checking
across the terminal post of the rotor diode is not •• Step 3:
recommended. • With your VOM set to ohms, cycle the switch to ON
Before rotor replacement, follow the checklist outlined and test for continuity (Figure 34).
below:
Figure 34 — Checking The Engine Switch
• Check Engine RPM
• Check Capacitor
• Check Output Receptacle & Wiring
• Check Circuit Breaker (AC)
• Check Circuit Breaker (DC)

3
- You should have continuity.
•• Step 4:
• Check Stator Power Winding
• Cycle the switch to OFF.
- You should not have continuity.
• Check Excitation Winding
• Check Bridge Diode
• Check 12VDC Coil
29
Pilot Lamp
Some early units were equipped with a green pilot lamp. If
this is the case, troubleshoot the lamp using the instructions
that follow;
•• Step 1:
•• Step 2:
• Remove the terminals from the lamp.
•• Step 3:
• With your VOM set to ohms, check for continuity
through the lamp (Figure 35).
Figure 35 — Checking The Pilot Lamp
3
- No continuity: Replace lamp.
30
Section 4 • Assembly
ASSEMBLY 4
31
Assembly • Section 4
32
Mounting The Rotor & Stator • Position the stator and the rear bearing carrier over
the rotor and align the feet with the mounting holes in
Position the generator/base plate assembly as shown in
the base plate (Figure 38).
figure 36, before mounting the stator assembly.
Figure 38 — Positioning The Stator
Figure 36 — Generator / Base Plate Assembly
• Install the bolts but do not tighten yet.

• Mount the rotor on the tapered shaft of the engine
(Figure 37). Make sure the stator is seated in the machined lands of its
cradle as shown in figure 39A and 39B.
Figure 39 — Seating The Statot Assembly
Figure 37 — Mount The Rotor
A B
With the stator properly seated in the machined lands of its

4
cradle:
NOTE: The rotor is not timed in any way.
33
• Install the three stator through-bolts and tighten until Before tightening the rotor mount bolt:
the rear bearing carrier is secure (Figure 40). • Check the orientation of the fan (Figure 42).
Figure 40 — Securing The Stator Assembly
Figure 42 — Cooling Fan Orientation
• Check to make sure there are no obstructions to the

rotation of the rotor assembly.
• Torque the through bolts to 85 lbs. in. Torque the rotor mount bolt to 100 lbs. in.
• Torque the mounting bolts in the feet of the rear
bearing carrier to 180 lbs. in. Install The Muffler Heat Shield
• Slip the rotor mount bolt through the cooling fan. Start • Slip the heat shield between the muffler and the
the bolt in the threads of the engine output shaft by generator until the mounting flanges of the rear bearing
hand (Figure 41). carrier align with the mounting flange of the heat shield
(Figure 43A & 43B).
4
Figure 41 — Installing Rotor Mount Bolt
Figure 43 — Generator Heat Shield
A B
34
• Install the mounting screws and tighten until the heat

shield is secure. Figure 45 — Harness Connectors
NOTE: Make sure that the bent angles of the heat

shield are in contact with surfaces of the engine as
shown in figure 44.
Figure 44 — Check Heat Shield Contact And Mounting
• Connect one lead of the engine run switch to the

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

The control panel that is mounted in the front case half is
connected to the generator by means of two four-pin cable
4
connectors. The associated wires colors are identical.
• Match the wire colors of the two harness connectors
and seat each connector until it locks into place
(Figure 45).
35
Mount The Rear Case Halve • Align the rear case half with the mounting holes in the
generator carriage.
• Position the unit as shown in figure 47.
• Refer to figure 49A & B and place the fasteners as shown.
Figure 47 — Unit Positioned For Closure
Figure 49 — Rear Case Half Fasteners
M6-16
A M6-20 B M6-20
• Mount the air cleaner housing to the two studs that
extend through the carburetor (Figure 48A).
The tank support brackets are shown in figure 50A & B.
• Insert the oil breather hose into the back of the air cleaner
housing (Figure 48B). • Insert the left-hand tank support bracket inside the case
stiffener and secure to the rear case half with a M5-16
screw with a medium pilot collar (Figure 50A).
Figure 48 — Breather Tube & Air Filter Housing
• Mount the right hand bracket as shown in figure 50B.
Figure 50 — Fuel Tank Support Brackets
4 M5-16
A B
NOTE: Make sure that the steel bushings are

installed in the housing for the air cleaner
A B
(Figure 48A).
The rear case half is mounted on the carriage first.
36
Mount The Fuel Tank Mount The Front Case Half

Inspect the tank for the following items; Before mounting the front case half, ensure that the LOS
• Ensure that the fuel strainer is installed in the bottom of module is oriented on its mounting as shown in figure 53.
the tank sump. Figure 53 — LOS Orientation
• Check that the rubber vibration seals are glued on the
seams of the fuel tank.
• Seat the tank in the area above the support brackets
(Figure 51).
Figure 51 — Mounting The Fuel Tank
• Position the front case half close enough to the generator

unit in order to make the wiring connections to the Low
Oil Sense (LOS) module and start switch (Figure 54).
Figure 54 — Start Switch & (LOS) Wiring

• Connect the fuel supply hose to the tank as shown in
figure 52.
Figure 52 — Connecting The Fuel Supply Hose
37
• Route the starter rope through its opening in the case.

Figure 57 — Wiring Harness Connections
• Align the front case half with the mounting points in the
generator carriage and install the fasteners (figure 55).
Figure 55 — Fastener Locations On Front Case Half
• Install the control panel face plate (Figure 58).
Figure 58 — Install Control Panel
With the mounting fasteners tight, connect the wiring

harness connectors through the opening of the control
panel (Figure 56).
Figure 56 — Access To Wiring Harness
4
• Install oil service cover (Figure 59).
• Match the colors of the wires.
NOTE: Match the color-coding of the wires to

make sure that you are making the proper
connections (Figure 57).
38
Figure 59 — Install Oil Service Door Figure 61 — Install Spill Well & Fuel Cap
• Install air filter assembly (Figure 60).
Figure 60 — Install Air Filter Assembly
4
• Install fuel spill well and fuel cap (Figure 61).
39
40
Section 5 • Appendix
APPENDIX 5
41
Appendix • Section 5
5
42
APPENDIX
Resistance Values Torque Specifications
Rotors: Engine:
(60HZ) 4.06 ohm Item Size Torque Value

(50HZ) 4.10 ohm (In. Lbs.)
Stators: Connecting Rod M6x30 85

Crankcase Cover M6x12 85
M8 180
(60HZ) Muffler M8 180
Excitation Winding 3.911 ohm Head Bolt M8x55 220
Power Winding 1.010 ohm Flywheel Nut M12 400
12VDC Winding .429 ohm Spark Plug M14 180
Oil Drain Plug M10 180
(50HZ) Cooling Fan 5/16" 85
Excitation Winding 4.79 ohm Pivot Bolt M8 180
Power Winding 4.33 ohm General Screws M5 35
12VDC Winding .510 ohm Rocker Arm Assy. M6x16 45
M8 180
CT Bolt M6 85
M8 180
Capacitors: Rocker Box Cover M6x12 45
(60HZ) 14 µFu
Generator:
(50HZ) 14 µFu
Rotor Bolt M6 100

Stator Bolt M6 85
Tapping Screw M6 45
General Screws M4 20
5
M5 35
M6 45
M8 180
43
Figure 62 — Fastener Sizes and Locations
M5-10
M5-10
M5-16
M6-20
M6-16
M5-16
M6-16
M6-16
5 M6-16
M6-20
44
Figure 63 — Fastener Sizes and Locations (Continued)
M6-90
M6-160
M8-12
M8-12
M8
Self-Tapping Screw
M8-12
5
45
5
46

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

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BRIGGS & STRATTON CORPORATION

Copyright © 2003 Briggs & Stratton Corporation

All rights reserved.

Hand-Held Series Generator

Copyright © 2003 Briggs & Stratton Corporation

All rights reserved.

In The Interest of Safety

In the Interest of Safety CAUTION: Indicates a hazard

DANGER WARNING Safety Practices

• Hand-held generators produce a very powerful

Item Nomenclature Item Nomenclature

1. Vibration Mount 11. Fuel Inlet Filter

Recoil Starter Fuel Cap

Oil Service Cover

Data Plate Recoil Starter

Spark Plug Access

Serial Number Locations Generator Specifications

1 Figure 3 — Engine Serial Number Location Engine:

Generator: N. American Europe

Continuous Operation: 6.4 Hours 6.4 Hours

Fuel System Components GENERAL SERVICE INFORMATION

Spill Well Hand Tools

General Disassembly Considerations NOTE: Do not attempt to remove the protective

Hand-held generators are built to close tolerances. The Case Separation

Figure 8 — Screws with ”Pilot Collar”

NOTE: When assembling plastic components, be

• Remove the screw that is next to the fuel shut-off valve

Figure 10 — Mounting Bracket Screw

Figure 11 — Remove Fuel Supply Hose

ACCESS TO GENERATOR COMPONENTS

Figure 12 — Access To Generator Components

Figure 13 — Generator Components

Figure 16 — Position For Rotor Removal / Inspection

A view of the electrical components that are mounted on

NOTE: Mark the face of the fan to ensure proper

•• Step 4: Figure 20 — Remove Stator Housing & Stator

Figure 18 — Hardware (Heat Shield / Stator Housing)

Figure 19 — Remove Stator Through-Bolts

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

Under Voltage (DC) Test A: - Check Engine RPM

Test C: - Check (DC) Circuit Breaker

Positive Probe (+)

NOTE: You must follow the Diode Test

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

"Over Voltage" (AC)

Test A: - Check Engine RPM

Test B: - Check Capacitor

The capacitor can be checked without disassembling the unit

Figure 27 — Short the Capacitor Terminals

Figure 28 — Testing the Capcitor

• Find the rating of the capacitor on its body or in the

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

Under Voltage (AC) Test C: - Check AC Circuit Breaker

•• Step 1: Figure 31 — Checking Circuit Breaker

Test D: - Check Stator Power Winding Test F: - Check Excitation Winding

Test E: - Check Capacitor

Test G: - Check Rotor Winding Engine Switch

• Check Engine RPM

• Check Output Receptacle & Wiring