another free manual from www.searstractormanuals.
ThePowerPortal.com Your “One Stop” Information Source another free manual from www.searstractormanuals.com Briggs & Stratton has developed a powerful and flexible private web-based portal for its family of products, ThePowerPortal.com. Power Portal Features ➤ Secure, on-demand, 24x7 access to meaningful information and functions for all of our products. ➤ Role-based security that will dynamically generate an interface and content which is specific to the various roles of the user.
Table of Contents Continuity Checks ‑ Switches DC Voltage Battery Test Resistance Checks Diode Checks V ..................................................................................................................... 2 .......................................................................................................................... 2 ...................................................................................................................................... 2 .......................
CONTINUITY CHECKS ‑ SWITCHES 1. Insert RED test lead into v meter. 2. Insert BLACK test lead into meter. another free manual from www.searstractormanuals.com 3. Rotate selector to PUSH BUTTON SWITCH (ELECTRIC START) receptacle in COM ROTARY KEY SWITCH receptacle in IGNITION STOP SWITCH position. 4. When meter test leads are attached to switch terminals and switch is in “ON” position, a continuous tone indicates continuity.
DIODE CHECKS In the Diode Test position, the meter will display the forward voltage drop across the diode(s). If the voltage drop is less than 0.7 volt, the meter will “beep” once, as well as display the voltage drop. A continuous tone indicates continuity (shorted diode). An incomplete circuit (open diode) will be displayed as “OL”. another free manual from www.searstractormanuals.com TEST LEAD FROM METER receptacle in 1. Insert RED test lead into v meter. 2. Insert BLACK test lead into meter.
RED Test Lead BLACK Test Lead Beep B A Yes C B Yes C D Yes D A Yes NOTE: Metal cased rectifiers must also be tested for “grounds”, as follows: With BLACK test lead probe contacting rectifier case, touch each terminal, A – D, with RED test lead probe. Meter should display “OL” at each terminal. If meter makes a continuous tone at any terminal, rectifier is defective (“grounded”). A another free manual from www.searstractormanuals.
FOR BLACK LEAD FROM METER RESISTANCE SECTION FOR RED LEAD FROM METER CONNECTS TO NEGATIVE BATTERY CABLE another free manual from www.searstractormanuals.com CONNECTS TO NEGATIVE BATTERY POST Previous Style Current Style Note: Meter and battery connections to shunt are the same as the previous DC shunt as shown above. OHM'S LAW FORMULA Some background information may help to make this clearer.
Now, let’s add charging current from the alternator system flowing through the shunt. Resistance through the shunt will stay the same. We know the current will change. Since the shunt measures voltage drop, we have to be interested in the voltage or pressure in the system. The resistance value of the shunt is set so that we know there is a 1 to 1 ratio between amps and millivolts. Therefore, a reading of 2 millivolts on the meter face is equal to 2 amps of current, 3 equals 3, etc.
DC SHUNT INSTRUCTIONS another free manual from www.searstractormanuals.com The DC shunt, part number 19468 readily adapts to standard mount, side mount or tab type battery terminals. The shunt must be installed on the - (negative) terminal of the battery. For standard terminals, attach ring terminal on shunt to post terminal on battery. For tab terminal batteries, attach shunt to battery terminal using 1/4" – 20 stud and wing nut.
NO‑LOAD STARTER CURRENT DRAW 12 VOLT STARTER MOTORS 300mV TEST LEAD FROM METER another free manual from www.searstractormanuals.com (STARTER MOTOR REMOVED FROM ENGINE) To check the no-load amperage draw of a 12 volt starter motor that is removed from the engine, a fixture as shown in the figure should be used. See the diagram for the parts necessary to make a test set-up. TEST LEAD FROM METER PRESS TO START CAUTION: DO NOT clamp motor housing in a vise.
STARTER CURRENT DRAW – 12 VOLT STARTER MOTORS 300mV another free manual from www.searstractormanuals.com (STARTER MOTOR MOUNTED ON ENGINE) To check the amperage draw of a starter motor mounted on the engine, the procedure is similar to checking the starter motor off the engine. The battery cable and key switch harness installed in the equipment may be substituted for the test harness shown.
AC VOLTAGE OUTPUT CHECK v 1. Insert RED test lead into v meter. 2. Insert BLACK test lead into meter. DUAL CIRCUIT receptacle in CONNECTOR COM receptacle in RED CLIP TO AC SIDE OF HARNESS (BLACK WIRE) 3. Rotate selector to position. 4. Attach RED test clip to alternator AC output terminal(s). another free manual from www.searstractormanuals.com 5. Attach BLACK test clip to engine ground.
DC AMPERAGE OUTPUT CHECK See Note Below For 1/2 Amp and System 3 & 4 Alternators “BUMP” ON CONNECTOR INDICATES THE DC OUTPUT PIN LOCATION AC OUTPUT PIN See Page 14 for Special Instructions on Checking DC Amperage Output of 16 and 20 Amp Regulated System receptacle in 1. Insert RED test lead into meter. another free manual from www.searstractormanuals.com 2. Insert BLACK test lead into meter. 3.
CHECKING DC AMPERAGE OUTPUT TEST LEAD 16 & 20 AMP REGULATED ALTERNATOR TEST LEAD To avoid blowing fuse in meter when testing DC output of 16 and 20 amp system the DC Shunt, Tool part number 19468, is required. another free manual from www.searstractormanuals.com The DC Shunt must be installed on the - (negative) terminal of the battery. All connections must be clean and tight for correct amperage readings. 1. Install shunt on negative battery terminal. receptacle in 2.
STARTER MOTOR CURRENT DRAW 120 VOLT STARTER MOTORS A CAUTION: If amperage is higher than specification in Table 4, immediately stop the test! An amperage reading higher than number in chart, indicates a shorted starter motor, which could be dangerous. Use Line Current Adapter, Tool part number 19358, when checking current draw on 120 volt starter motors. Use the same test fixture used in the 12 volt starter test to check the current draw and free running RPM of motor. another free manual from www.
Electric Starter Kits Quick Reference Engine Model Starter Assembly# Starter Gear Only# Drive Assy. # (Bendix) Single Cylinder Engines 190400-196499 497595 (Plastic Ring Gear) 695708 (Plastic Ring Gear) 696541 (C Ring Type) 190700-195799 693054 (Alum. Ring Gear) 693059 (Alum.
ALTERNATOR IDENTIFICATION another free manual from www.searstractormanuals.com Briggs & Stratton engines are equipped with a number of different alternator systems to meet the requirements of equipment manufacturers. For example, a large lawn tractor with accessories may require a 16 amp regulated system, whereas a snow thrower with a single headlight requires an AC Only system. Knowing the type of alternator system an engine is equipped with is important, particularly when an engine is being replaced.
LEAD AC OUTPUT LEAD DC OUTPUT TO EQUIPMENT HARNESS LEADS FROM ENGINE (STATOR) CONNECTOR OUTPUT LEAD DC CHARGING CIRCUIT RED LEAD TO EQUIPMENT HARNESS ONE RED LEAD TWO BLACK LEADS FROM ENGINE (STATOR) CONNECTOR LEAD AC FOR LIGHTS another free manual from www.searstractormanuals.com AC Only • 3 amp DC unregulated for charging battery (ONE RED lead from stator). • 14 Volts AC for lighting circuit (ONE BLACK lead from stator). • Diode encased at connector. • White connector with two pin terminals.
ENGINE/ALTERNATOR REPLACEMENT INFORMATION another free manual from www.searstractormanuals.com With the exception of the AC Only alternator, all of the alternator systems referred to in this book have a battery as part of the electrical system. There are specialized applications that use an alternator without a battery. An example would be certain generators or welders that use alternator output to excite an electrical field.
The following are alternator replacement combinations which require an adapter harness. All of the necessary components are shown. 1. Original engine equipped with AC Only alternator. Replacement engine equipped with Dual Circuit alternator. another free manual from www.searstractormanuals.com Modify 398661 harness supplied with replacement engine by removing RED DC wire. Then, splice 393537 connector into white AC wire and connect to equipment harness.
3. Original engine equipped with Dual Circuit alternator. Replacement engine equipped with 5, 9, 10 or 16 amp regulated system. Modify 692306 harness supplied with replacement engine by splicing in 399916 connector assembly. Connect to equipment harness. 399916 CONNECTOR ASSEMBLY SPLICE OUTPUT CONNECTOR FROM REGULATOR another free manual from www.searstractormanuals.com EQUIPMENT HARNESS 692306 HARNESS RIB RIB 4. Original engine equipped with Tri-Circuit alternator.
5. Original engine equipped with Dual Circuit alternator. Replacement engine equipped Tri-Circuit alternator. Discard 691955 diode harness supplied with new engine. Install 794360 regulator/rectifier. Add 692306 harness and modify by splicing in 399916 connector assembly. Connect to equipment harness. 399916 CONNECTOR ASSEMBLY another free manual from www.searstractormanuals.com OUTPUT CONNECTOR FROM ALTERNATOR SPLICE 393422 HARNESS RIB RIB EQUIPMENT HARNESS 794360 REGULATOR/RECTIFIER 6.
BRIGGS & STRATTON ENGINE REPLACING ENGINE OF ANOTHER MANUFACTURER When replacing the engine of another manufacturer with a Briggs & Stratton engine, the equipment requirements must be known so that the replacement alternator system has the same output as the original system provided. another free manual from www.searstractormanuals.com Often the equipment wiring harness is not compatible with the Briggs & Stratton alternator output harness.
ALTERNATOR DIODE another free manual from www.searstractormanuals.com STOP SWITCH TERMINAL ANTI-AFTERFIRE SOLENOID AC OUTPUT WIRE KEY SWITCH DC OUTPUT WIRE 2 3 1 5 4 + AMMETER SOLENOID TAB TERMINAL − HEADLIGHTS HEADLIGHT SWITCH STARTER TERMINAL BATTERY TERMINAL SOLENOID + - STARTER MOTOR 12 VOLT BATTERY Typical Dual Circuit Alternator Wiring Diagram Original 5 Pole Switch Superceded to 6 Pole Switch, Briggs & Stratton Part Number 692318 Key Switch Test Switch Position Terminal No.
STOP SWITCH TERMINAL ANTI-AFTERFIRE SOLENOID ALTERNATOR another free manual from www.searstractormanuals.
24 BATTERY WHITE CONNECTOR BLACK AC OUTPUT Typical Dual Circuit System RED DC OUTPUT DIODE STATOR START SWITCH 5 1 3 2 4 STARTER SOLENOID another free manual from www.searstractormanuals.
STOP SWITCH TERMINAL ANTI-AFTERFIRE SOLENOID ALTERNATOR KEY SWITCH another free manual from www.searstractormanuals.com AC OUTPUT WIRE DC OUTPUT WIRE REGULATOR/ RECTIFIER 2 3 1 5 4 + AMMETER − SOLENOID TAB TERMINAL BATTERY TERMINAL STARTER TERMINAL HEADLIGHTS SOLENOID HEADLIGHT SWITCH + - STARTER MOTOR 12 VOLT BATTERY Typical 16 Amp Regulated Alternator Wiring Diagram 5 Pole Switch − Briggs & Stratton Part Number 692318 Key Switch Test Switch Position Terminal No.
STOP SWITCH TERMINAL ANTI-AFTERFIRE SOLENOID ALTERNATOR KEY SWITCH another free manual from www.searstractormanuals.
another free manual from www.searstractormanuals.
28 STARTER ALTERNATOR GROUND WIRE TERMINAL BATTERY LIGHT SWITCH SEAT SWITCH AMMETER Typical 10/16 Amp System ELECTRIC CLUTCH STARTER RELAY - + A B A B D C E C another free manual from www.searstractormanuals.
TRI-CIRCUIT STATOR STOP SWITCH TERMINAL ANTI-AFTERFIRE SOLENOID ALTERNATOR another free manual from www.searstractormanuals.
TRI-CIRCUIT STATOR AC OUTPUT WIRE ALTERNATOR STOP SWITCH TERMINAL ANTI-AFTERFIRE SOLENOID another free manual from www.searstractormanuals.
31 B C LIGHT SWITCH A D E PTO SWITCH 1 GREEN CONNECTOR INTERLOCK SWITCH Simplified “Tri-Circuit” System STATOR 25W RESISTOR BATTERY STARTER SOLENOID CLUTCH another free manual from www.searstractormanuals.
32 + − AMMETER 2+5 CLUTCH SWITCH ELECTRIC CLUTCH RESISTOR B A + SEE NOTE ANTI-AFTERFIRE SOLENOID 5 2 12 VOLT BATTERY SOLENOID BATTERY TERMINAL 1 3 KEY SWITCH 4 − STARTER TERMINAL SOLENOID TAB TERMINAL STOP SWITCH TERMINAL STARTER MOTOR Typical Tri-Circuit Alternator Wiring Diagram – With Resistor – 5 Pole Switch − Briggs & Stratton Part Number 692318 *Terminal 1 Grounded Internally To Key Switch Case 2+4+5 2. RUN 3. START *1 + 3 Continuity 1.
33 − CLUTCH DPDT SWITCH ON OFF ELECTRIC CLUTCH RESISTOR BATTERY TERMINAL + ANTI-AFTERFIRE SOLENOID 12 VOLT BATTERY SOLENOID 5 1 6 3 2 KEY SWITCH 4 − STARTER TERMINAL STARTER MOTOR SOLENOID TAB TERMINAL STOP SWITCH TERMINAL Typical Tri-Circuit Alternator Wiring Diagram – With Resistor – 6 Pole Switch − Briggs & Stratton Part Number 692318 *Terminal 1 Grounded Internally To Key Switch Case 2+4+5 2+5 2. RUN 3.
34 START SWITCH 5 1 3 2 4 BATTERY A B D C E A STATOR SEAT SWITCH B D C B A CLUTCH/ BRAKE SWITCH FUSE Typical Complex Tri-Circuit System GREEN CONNECTOR PTO SWITCH - + LIGHT SWITCH A PTO CLUTCH B another free manual from www.searstractormanuals.
V-Twin Wire Harness another free manual from www.searstractormanuals.
F 36 1 2 3 2 E 9 15 D SEE DETAIL K A DETAIL “K” KEY 6 DIODES CRIMPED CONNECTION 14 15 SHRINK TUBING 6 PIN CONNECTOR DETAIL K 14 JUMPER WIRE BETWEEN 1&4 6 4 3 3 2 1 6 5 4 "ROUTE" TO TERMINAL HOLE No's AS SHOWN. RIB E EACH DIODE ASSEMBLY MUST BE INDIVIDUALLY WRAPPED IN SHRINK TUBING. AN ADDITIONAL SHRINK WRAP MUST ALSO BE ASSEMBLED OVER BOTH DIODE ASSEMBLIES.
THERMISTOR (SIGNAL) THERMISTOR (GND) 2 SIGNAL 2-WAY CONNECTOR 12 VOLT POWER (+) ----12 VOLT POWER (GND) 12 VOLT POWER (+) --- 12 VOLT POWER (GND) SIGNAL --- 1 TERMINAL # TERMINAL # 1 2 3 4 5 6 7 8 8-WAY CONNECTOR 37 STATOR YELLOW RED RED 6 2 3 7 4 GRAY 1 5 & 9 AMP CIRCUIT OPTION POWER SUPPLY FROM REGUALTOR OPEN OPEN 6 CARB SOLENOID 3 5 CYLINDER #1 & #2 ARMATURE 2 4 POWER SUPPLY FROM REGULATOR 5 6 3 RED - - RED GRAY BLACK RED WIRE COLOR 6 PIN CONNECTOR (ENGINE SIDE)
WIRE CONNECTORS V-TWIN 6 PIN CONNECTOR ENGINE CONNECTION APPLICATION CONNECTION AMP PIN HOUSING (FEMALE-CAP) AMP SOCKET HOUSING (MALE-PLUG) RIB IS AT HOLE #1 TO LIGHT SWITCH HOLE #4 "LIGHT SWITCH" COLOR: ORANGE HOLE #1 "ALTERNATOR" COLOR: RED another free manual from www.searstractormanuals.
39 OPEN SLOT TERMINAL END OIL PRESSURE (GREEN) IGNITION KILL (BLACK) GROUND (BROWN) VIEW FROM TERMINAL END FUEL CUT-OFF (GRAY) OPEN SLOT STARTER SOLENOID TAB (YELLOW) VOLTAGE REGULATOR (RED) OIL PRESSURE (GREEN) CUSTOMER CONNECTION STARTER SOLENOID BATTERY + (ORANGE) WIRE END Bottom View Right Side View Top View Left Side View typical 8-pin connector another free manual from www.searstractormanuals.com WIRE END 13 TO FIT INDAK KEY SWITCH FOR .
PERFORMANCE CONTROL™ ELECTRONIC GOVERNOR another free manual from www.searstractormanuals.com Some Vanguard™ V-Twin engines are equipped with the Performance Control™ electronic governor control system for generator or welder applications. The electronic governor provides more responsive governing than a mechanical governor system. Engines equipped with the Performance Control™ electronic governor control system have no mechanical governor components.
AWG Wire Sizes (see table on the next page) AWG: In the American Wire Gauge (AWG), diameters can be calculated by applying the formula D(AWG)=.005·92((36-AWG)/39) inch. For the 00, 000, 0000 etc. gauges you use -1, -2, -3, which makes more sense mathematically than “double nought.” This means that in American wire gage every 6 gauge decrease gives a doubling of the wire diameter, and every 3 gauge decrease doubles the wire cross sectional area. Similar to dB in signal and power levels.
another free manual from www.searstractormanuals.com AWG gauge Conductor Diameter Inches Conductor Diameter mm Ohms per 1000 ft. Ohms per km 0000 000 00 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Metric 2.0 33 Metric 1.8 34 Metric 1.6 35 Metric 1.4 36 Metric 1.25 37 Metric 1.12 38 Metric 1 39 40 0.46 0.4096 0.3648 0.3249 0.2893 0.2576 0.2294 0.2043 0.1819 0.162 0.1443 0.1285 0.1144 0.1019 0.0907 0.0808 0.072 0.0641 0.0571 0.0508 0.0453 0.0403 0.0359 0.
43 Red to V Regulated two output pins with heat sink Regulated two output pin Regulated one output pin Tri Circuit 28 volts AC Output From Regulator From Stator From Regulator From Stator Red to V Red to V Red to V Red to V Red to V Red to V Red to V 300mV Volts AC 300mV Volts AC 300mV Volts AC 300mV Volts AC Volts AC Shunt on Negative Terminal Yellow Wire Shunt on Negative Terminal Either Pin Shunt on Negative Terminal Shunt on Negative Terminal Red to 10 amp Wiring & diod
GLOSSARY OF TERMS In this day of lightning fast communications and an ever increasing level of sophistication in our day to day activities, the spoken word has become one of the most important tools in our toolboxes. “Word Power” is the natural extension of your thought processes. Without a high caliber vocabulary, communication with our peers and/or our customers can be severely hampered.
core: The laminations in the generator constituting the magnetic structure thereof. cradle: The metal frame that surrounds and protects the generator/engine. current: The flow of electrons moving past a point in a circuit. cycle: One complete wave of alternating voltage that contains 360 degrees. another free manual from www.searstractormanuals.
inductive field coil: A coil of wire, attached to a segmented iron core, that produces a magnetic field when current is passed through it. ionization gap: The distance between the ignition armature pole and the secondary pole in the spark tester. L another free manual from www.searstractormanuals.com lamination stack: An electrical component that consists of thin iron layers used to focus and control the lines of magnetic flux.
rated voltage: The rated voltage of an engine generator set is the voltage at which it is designed to operate. rear bearing carrier: The casting which houses the rotor bearing which supports the rotor shaft. rectifier: An electrical component that converts AC to DC by allowing the current to flow in only one direction. another free manual from www.searstractormanuals.com regulator/rectifier: An electrical component that contains one or more diodes and a zener diode.
watt: Unit of electrical power. In DC equals volts times amperes. In AC equals effective volts times effective amps times power factor times a consistent dependent on the number of phases. 1 kilowatt – 1,000 watts. another free manual from www.searstractormanuals.com winding: All the coils of a generator. Stator winding consists of a number stator coils and their interconnections. Rotor windings consist of all windings and connections on the rotor poles.
Briggs & Stratton Alternator Chart You can order this chart from your source of supply or on ThePowerPortal.com under Customer Education. MS-2288FL.qxp 10/23/2008 10:24 Page 1 BRIGGS & STRATTON ALTERNATOR CHART DC only Alternator another free manual from www.searstractormanuals.com 0.5 Amp DC unregulated Output @ 2800 rpm Engine 0.5 Amp DC unregulated 97700 99700 100600 100800 110000 120000 1.5 Amp DC unregulated Engine 110000 120000 200000 White Connector 1 Red Wire 1.
BRIGGS&STRATTON CUSTOMER EDUCATION For more educational information contact us at 1-800-934-7730 or e-mail us at cust.ed@basco.com BRIGGSandSTRATTON.com • ThePowerPortal.com IDN Network CSSD / IDN EDUCATIONAL DIRECTORS DELTA BRITISH COLUMBIA ALBERTA SASKATCHEWAN MANITOBA ONTARIO QUEBEC CLACKAMAS another free manual from www.searstractormanuals.
