Simplicity 030430 User manual

Service and Repair Manual

5500 Watt Portable Generator — Model 030430

This generator is rated in accordance with CSA (Canadian Standards

Association) standard C22.2 No. 100-04 (motors and generators).

Manual No. 279787GS Revision A

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

2 BRIGGSandSTRATTON.COM

Briggs & Stratton Power Products Group, LLC

P.O. Box 702

Milwaukee, WI 53201-0702

may be reproduced or transmitted in any form without the express

written permission of Briggs & Stratton Power Products Group, LLC.

3

Table of Contents

Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4

Generator Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Alternator Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Generator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 10

Alternator Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Generator Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 20

Generator Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fuel System and Carburetion . . . . . . . . . . . . . . . . . . . . . . . 29

Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cylinders, Covers, and Sumps . . . . . . . . . . . . . . . . . . . . . . 43

Crankshafts and Camshafts . . . . . . . . . . . . . . . . . . . . . . . . 45

Piston, Rings, and Connecting Rod . . . . . . . . . . . . . . . . . . 47

Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Generator Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . 57

Engine Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . 65

4 BRIGGSandSTRATTON.COM

Save These Instructions

The safety alert symbol indicates a potential personal

injury hazard. A signal word (DANGER, WARNING, or

CAUTION) is used with the alert symbol to designate a degree

or level of hazard seriousness. A safety symbol may be used

to represent the type of hazard. The signal word NOTICE is

used to address practices not related to personal injury.

DANGER indicates a hazard which, if not avoided, will

result in death or serious injury.

WARNING indicates a hazard which, if not avoided, could

result in death or serious injury.

CAUTION indicates a hazard which, if not avoided, could

result in minor or moderate injury.

NOTICE addresses practices not related to personal injury.

Important Safety Instructions

The manufacturer cannot possibly anticipate every possible

circumstance that might involve a hazard. The warnings in

this manual, and the tags and decals affixed to the unit are,

therefore, not all-inclusive. If you use a procedure, work

method or operating technique that the manufacturer does

not specifically recommend, you must satisfy yourself that

it is safe for you and others. You must also make sure that

the procedure, work method or operating technique that you

choose does not render the generator system unsafe.

Safety Symbols and Meanings

Equipment Description

Read this manual carefully and become familiar

with your generator. Know its applications, its

limitations and any hazards involved.

The generator is an engine-driven, revolving field, alternating

current (AC) generator. It was designed to supply electrical

power for operating compatible electrical lighting, appliances,

tools and motor loads. The generator’s revolving field is

driven at about 3,600 rpm by a single-cylinder engine.

NOTICE: Exceeding generator’s wattage/amperage capacity

could damage generator and/or electrical devices connected

to it.

• DO NOT exceed the generator’s wattage/amperage

capacity.

Every effort has been made to ensure that the information

in this manual is both accurate and current. However, the

manufacturer reserves the right to change, alter, or otherwise

improve the generator and the documentation at any time

without prior notice.

The Emission Control System for this generator is warranted

for standards set by the Environmental Protection Agency and

the California Air Resources Board.

Toxic Fumes

Kickback

Electrical Shock

Fire

Explosion

Read Manual

Hot SurfaceFlying Objects

Moving Parts

5

WARNING Running engine gives off carbon monoxide,

an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache,

fatigue, dizziness, vomiting, confusion, seizures,

nausea, fainting or death.

Operate generator ONLY outdoors.•

Install a battery operated carbon monoxide alarm near •

the bedrooms.

Keep exhaust gas from entering a confined area through •

windows, doors, ventilation intakes, or other openings.

DO NOT operate this product inside any building, carport, •

porch, mobile equipment, marine applications, or

enclosure, even if windows and doors are open.

WARNING The engine exhaust from this product

contains chemicals known to the State of California to

cause cancer, birth defects, or other reproductive harm.

WARNING Certain components in this product and

related accessories contain chemicals known to the

State of California to cause cancer, birth defects, or

other reproductive harm. Wash hands after handling.

WARNING

This generator does not meet U.S. Coast Guard •

Regulation 33CFR-183 and should not be used on marine

applications.

Failure to use the appropriate U.S. Coast Guard approved •

generator could result in death or serious injury and/or

property damage.

WARNING Starter cord kickback (rapid retraction)

will pull hand and arm toward engine faster than

you can let go, which could cause broken bones,

fractures, bruises, or sprains resulting in serious

injury.

When starting engine, pull cord slowly until resistance is •

felt and then pull rapidly to avoid kickback.

NEVER start or stop engine with electrical devices •

plugged in and turned on.

WARNING Fuel and its vapors are extremely

flammable and explosive which could cause

burns, fire or explosion resulting in death,

serious injury and/or property damage.

WHEN ADDING OR DRAINING FUEL

Turn generator engine OFF and let it cool at least 2 •

minutes before removing fuel cap. Loosen cap slowly to

relieve pressure in tank.

Fill or drain fuel tank outdoors.•

DO NOT overfill tank. Allow space for fuel expansion.•

If fuel spills, wait until it evaporates before starting engine.•

Keep fuel away from sparks, open flames, pilot lights, •

heat, and other ignition sources.

Check fuel lines, tank, cap and fittings frequently for •

cracks or leaks. Replace if necessary.

DO NOT light a cigarette or smoke.•

WHEN STARTING EQUIPMENT

Ensure spark plug, muffler, fuel cap, and air cleaner are in •

place.

DO NOT crank engine with spark plug removed.•

WHEN OPERATING EQUIPMENT

DO NOT operate this product inside any building, carport, •

porch, mobile equipment, marine applications, or

enclosure.

DO NOT tip engine or equipment at angle which causes •

fuel to spill.

DO NOT stop engine by moving choke control to “Choke” •

position ( ).

WHEN TRANSPORTING, MOVING OR REPAIRING EQUIPMENT

Transport/move/repair with fuel tank EMPTY or with fuel •

shutoff valve OFF.

DO NOT tip engine or equipment at angle which causes •

fuel to spill.

Disconnect spark plug wire.•

WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK

Store away from furnaces, stoves, water heaters, clothes •

dryers, or other appliances that have pilot light or other

ignition source because they could ignite fuel vapors.

6 BRIGGSandSTRATTON.COM

WARNING Generator voltage could cause electrical

shock or burn resulting in death or serious injury.

Use approved transfer equipment to prevent backfeed by •

isolating generator from electric utility workers.

When using generator for backup power, notify utility company.•

Use a ground fault circuit interrupter (GFCI) in any damp or •

highly conductive area, such as metal decking or steel work.

DO NOT touch bare wires or receptacles.•

DO NOT use generator with electrical cords which are •

worn, frayed, bare or otherwise damaged.

DO NOT operate generator in the rain or wet weather.•

DO NOT handle generator or electrical cords while standing •

in water, while barefoot, or while hands and feet are wet.

DO NOT allow unqualified persons or children to operate •

or service generator.

WARNING Exhaust heat/gases could ignite

combustibles, structures or damage fuel

tank causing a fire, resulting in death,

serious injury and/or property damage.

Contact with muffler area could cause burns resulting in

serious injury.

DO NOT touch hot parts and AVOID hot exhaust gases.•

Allow equipment to cool before touching.•

Keep at least 5 feet (152 cm) of clearance on all sides of •

generator including overhead.

It is a violation of California Public Resource Code, •

Section 4442, to use or operate the engine on any forest-

covered, brush-covered, or grass-covered land unless

the exhaust system is equipped with a spark arrester, as

defined in Section 4442, maintained in effective working

order. Other states or federal jurisdictions may have

similar laws.

Contact the original equipment manufacturer, retailer, or

dealer to obtain a spark arrester designed for the exhaust

system installed on this engine.

Replacement parts must be the same and installed in the •

same position as the original parts.

WARNING Unintentional sparking could cause fire or

electric shock resulting in death or serious

injury.

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR GENERATOR

Disconnect the spark plug wire from the spark plug and •

place the wire where it cannot contact spark plug.

WHEN TESTING FOR ENGINE SPARK

Use approved spark plug tester.•

DO NOT check for spark with spark plug removed.•

WARNING Starter and other rotating parts could

entangle hands, hair, clothing, or accessories

resulting in serious injury.

NEVER operate generator without protective housing or •

covers.

DO NOT wear loose clothing, jewelry or anything that •

could be caught in the starter or other rotating parts.

Tie up long hair and remove jewelry.•

WARNING Excessively high operating speeds

could result in minor injury and/or generator damage.

Excessively low speeds impose a heavy load.

DO NOT tamper with governor spring, links, or other parts •

to increase engine speed. Generator supplies correct rated

frequency and voltage when running at governed speed.

DO NOT modify generator in any way.•

NOTICE Improper treatment of generator can damage it

and shorten its life.

Use generator only for intended uses.•

If you have questions about intended use, contact your •

authorized dealer.

Operate generator only on level surfaces.•

DO NOT expose generator to excessive moisture, dust, •

dirt, or corrosive vapors.

DO NOT insert any objects through cooling slots.•

If connected devices overheat, turn them off and •

disconnect them from generator.

Shut off generator if:•

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

NOTICE Exceeding generators wattage/amperage capacity

can damage generator and/or electrical devices connected

to it.

DO NOT exceed the generator’s wattage/amperage •

capacity.

Start generator and let engine stabilize before connecting •

electrical loads.

Connect electrical loads in OFF position, then turn ON for •

operation.

Turn electrical loads OFF and disconnect from generator •

before stopping generator.

7

Generator Components

A - Fuel Tank — Capacity of seven (7) U.S. gallons (26.5 L)

B - Fuel Valve — Used to turn fuel supply on and off to

engine.

C - Choke Lever — Used when starting a cold engine.

D - Air Cleaner — Protects engine by filtering dust and

debris out of intake air.

E - Recoil Starter — Used to start the engine.

F - Engine Rocker Switch — Set this switch to “ON” before

using recoil starter. Set switch to “OFF” to stop engine.

G - Oil Fill Cap — Check and fill engine with oil here.

H - Oil Drain Plug — Drain engine oil here

J - Grounding Fastener — Consult your local agency having

jurisdiction for grounding requirements in your area.

K - Identification Label — Provides model, revision, and

serial number of generator. Please have this readily

available when calling for assistance.

L - Rocker Switch Circuit Breaker — The receptacles are

provided with a rocker switch circuit breaker to protect

the generator against electrical overload.

M - 120/240 Volt AC, 30 Amp Locking Receptacle — May

be used to supply electrical power for the operation of

120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz

electrical, lighting, appliance, tool, and motor loads.

N - Spark Arrester Muffler — Exhaust muffler lowers engine

noise and is equipped with a spark arrester screen.

P - Engine Data Tag — Provides model, type, trim, and date

code for the engine.

R - 120 Volt AC, 20 Amp, Duplex Receptacles — May be

used to supply electrical power for the operation of 120

Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting,

appliance, tool, and motor loads.

A

B

C

D

E

F

G

H

J

K

L

M

N

R

P

8 BRIGGSandSTRATTON.COM

Alternator Components

A - Alternator Adapter

B - Rotor Assembly

C - Slip Rings

D - Stator

E - Roll Pin

F - Rear Bearing Carrier

G - Taptite

H - Brush Holder / Bridge Rectifier Assembly

J - Hex-Head Cap Screw

G

E

C

B

A

E

J

H

F

D

9

Brush Holder / Bridge Rectifier Assembly

The brush holder is mounted to the rear bearing carrier. The

positive (+) brush contacts the slip ring nearest the rotor

bearing.

The bridge rectifier is made up of four diodes and a varistor,

shown schematically in Figure 2. The diode (rectifier) permits

current flow in one direction only. Stator excitation winding

(AC) output leads connect to the two terminals labeled J1 and

J2 (C, Figure 1) located on top of the bridge rectifier. Direct

current (DC) is taken from the bridge rectifier and applied

to the rotor via the brush and slip rings. The varistor is a

“variable resistor” which protects the diodes against high

voltage surges.

This generator is equipped with a bridge rectifier (A, Figure 1)

attached to the brush holder assembly (B).

How it Works

Figure 3 is an operating diagram of a revolving field

alternator with a bridge rectifier.

Figure 3

Figure 1

B

C

A

Figure 2

A - Rotor

B - Magnetic Lines of Flux

C - Excitation Winding

B

C

E

F

G

NOTICE: The brushes are made of a carbon material and

can easily break. Use care when removing and installing the

brushes.

D - Bridge Rectifier

E - Power Winding

F - Receptacle

G - Slip Ring

The brush rectiﬁ er acts to supply direct current (DC) ﬂ ow to

the rotor winding. The increase in current ﬂ ow through the

rotor results in a proportional increase in the rotor’s magnetic

ﬁ eld strength, which induces alternating currect (AC) in the

windings of the stator.

1. The rotor (A) may be considered a permanent magnet

since some residual magnetism is always present in the

steel laminations.

2. The rotor (A) is rotated at a pre-determined speed.

3. Residual or “stored” magnetism in the rotor winding

creates magnetic lines of flux (B) which cut through

stator excitation winding (C) and power winding (E), to

induce Electro Motive Force (EMF) into both windings.

4. Winding (C) is the excitation winding. The EMF induced

into this winding produces an alternating currect (AC)

flow, which is applied to a bridge rectifier (D).

5. The bridge rectifier changes alternating current (AC)

into direct current (DC).

6. Direct current (DC) from the bridge rectifier is applied

to the rotor windings (A) via the slip rings (G) and

brush assembly, to create a magnetic field that is

stronger than that created by the residual magnetism of

the rotor.

7. This stronger magnetic field induces a greater EMF

(and resulting current flow) into both stator windings

(C and E).

8. The cycle then repeats itself until a predetermined

(AC) output is reached. Any load(s) connected to the

receptacle (F) completes circuit.

D

A

10 BRIGGSandSTRATTON.COM

Generator Troubleshooting

Figure 4

Refer to Figure 4 for wire identification and locations when

performing the troubleshooting procedures.

LEGEND

WIRE NUMBER WIRE COLOR

0 Green

2 Red

6 Blue

11 Blue

22 Red

33 Black

44 Gray

11

Figure 5 is a troubleshooting flowchart for “Direct Excited”

(Brush Type) generators.

Test 1:

Check AC output

voltage and frequency

Test 2:

Flash the Field

Test 3:

Isolate Control Panel

Low voltage

less than 1

volt or zero ?

Low voltage

and frequency

Output

OK?

END

See:

Check Alternator

Inspect Control

Panel

Output

OK

at

Harness?

Check and Adjust

Engine Governor

YES

NO

YES

Figure 5

Output

OK?

YES

NO

END

12 BRIGGSandSTRATTON.COM

In normal generator operation, upon startup there is some

“residual” magnetism in the rotor to get the generating

process started. Residual magnetism is what is left in the

rotor after the unit has shut down. When residual magnetism

is lost, the unit will have an output voltage that will remain

at zero. This usually occurs if the unit is out of use for a long

period of time. If residual magnetism is lost, it can usually be

restored by “ﬂ ashing the ﬁ eld” with a simple process involv-

ing a (DC) battery.

1. Obtain a 12VDC battery and two jumper leads with

alligator clip ends.

2. Remove the four screws and remove the rear bearing

cover.

3. Locate the brush/bridge rectifier inside the rear bearing

carrier.

4. Remove wires #2 and #6 (red and blue) from the

rectifier terminals J1 and J2.

NOTICE: Isolate wires #2 and #6. Do not let the terminals

touch or contact ground.

5. Apply 12VDC across terminals J1 and J2, polarity is

not important. Connect battery negative last (Figure 6).

6. Start the engine and allow it to stabilize at running

speed.

7. After about 5 seconds, shut the engine down.

8. Disconnect the battery wires from the brushes.

(Disconnect negative (-) battery wire last).

9. Restart the unit and check once again for proper (AC)

output voltage.

• If output voltage is within specifications,

troubleshooting is complete.

• If output voltage is not within specifications, proceed to

Test 3- Isolate Control Panel.

WARNING Battery posts, terminals and other

components in this product and related accessories

contain chemicals known to the State of California to

cause cancer, birth defects, or other reproductive harm.

Wash hands after handling.

WARNING Starter and other rotating parts could

entangle hands, hair, clothing, or accessories

resulting in serious injury.

NEVER operate generator without protective housing or •

covers.

DO NOT wear loose clothing, jewelry or anything that •

could be caught in the starter or other rotating parts.

Tie up long hair and remove jewelry.•

TEST 1 - Check Voltage and Frequency Output

1. Disconnect any electrical loads.

2. Check all circuit breakers and verify they are ON.

3. Set meter to measure AC volts.

4. Connect the meter test leads into a 120 VAC generator

receptacle.

5. Connect a frequency meter into a generator receptacle.

6. Start the generator engine, let it stabilize and warm up.

7. Read the “no-load” voltage and frequency, and analyze

the results as follows:

• If zero volts or less than 1VAC is indicated proceed to

Test 2 - Flash the Field.

• If low voltage is indicated, but readings is above 1VAC

and AC frequency is normal proceed to Test 3 - Isolate

the Control Panel.

• If low voltage is indicated, but reading is above 6VAC

and AC frequency is low the engine governor may need

adjustment. Refer to the appropriate engine manual for

further governor troubleshooting.

TEST 2 - Flash the Field

WARNING Generator voltage could cause electrical

shock or burn resulting in death or serious injury.

DO NOT touch bare wires or receptacles.•

DO NOT allow unqualified persons or children to operate •

or service generator.

Figure 6

13

TEST 3 - Isolate Control Panel

A “No Output” condition may or may not be related to the

alternator windings. To help isolate where the issue is, follow

these steps:

1. With the engine OFF, disconnect the power lead

harness from the back of the control panel.

2. Set meter to measure AC volts.

3. Connect the test leads to the stator wires #11 and #22

located in the control panel connector. Polarity does

not matter.

4. Start the engine and measure the voltage output.

5. Shut off the engine.

• A voltage output of 120VAC indicates the alternator

is functioning, and the no output condition is likely in

the control panel. Disassemble the control panel and

inspect for any indication of what may cause no output.

Refer to the unit wiring diagram to verify connections.

• A low voltage output indicates the alternator needs to

be tested. Proceed to Check Alternator.

Check Alternator

Alternator Disassembly

The alternator can be diagnosed without complete disassem-

bly. To access the power winding, disconnect the connector

from the back of the control panel. The Brush Rectiﬁ er (D)

is mounted inside the rear bearing carrier (E, Figure 7). To

access the brush rectiﬁ er, remove the four screws (A) and

remove the plastic, rear bearing cover (B).

Remove the two screws (C) and carefully pull out the

brushes. Disconnect wires #2 and #6 (excitation winding).

Once removed, the rotor slip rings can be accessed through

the area where the brushes were mounted.

NOTICE: The brushes are made of a carbon material and

can easily break. Use care when removing and installing the

brushes.

Figure 7

A

C

B

D

E

14 BRIGGSandSTRATTON.COM

Measure Winding Resistance

Test Stator AC Power Winding Resistance

1. Set meter to measure Ohms.

2. Connect the test leads to stator wires #11 and #22

located in the harness going to the control panel

connector (Figure 8).

3. Measure the resistance and compare it the nominal

resistance from the specifications listed in the back of

this manual.

4. Connect the test leads to stator wires #33 and #44

located in the control panel connector (Figures 9).

5. Measure the resistance and compare it to the nominal

resistance listed in the back of this manual.

• A reading within the specifications listed is acceptable.

• A reading of infinity or high resistance indicates an

opening in the power winding. Replace the stator.

• A low reading indicates a shorted stator winding.

Replace the stator.

6. Connect one meter test lead to a proper ground on

alternator. Connect the other test lead to the stator

power winding.

• A reading of infinity should be measured. If a reading

of infinity is measured and the stator resistance is

within specifications, the stator is functioning properly.

• A reading other than infinity indicates a stator winding

shorted to ground. Replace the stator.

Figure 8

Figure 9

15

Test Stator Excitation Winding Resistance

The excitation wires may be colored (red and blue) or

numbered (#2 and #6). Colored excitation wires must not be

confused with the colored power wires. The excitation wires

were disconnect earlier from the brush rectiﬁ er earlier in

Measuring Winding Resistance.

1. Set meter to measure Ohms.

2. Connect the test lead to the stator excitation wires

#2 and #6 (Figure 10). These wires were previously

disconnected from the brush rectifier.

Figure 10

3. Measure the resistance and compare it to the nominal

resistance listed in the back of this manual.

• A reading within the specifications listed is acceptable.

• A reading of infinity or high resistance indicates an

opening in the power winding. Replace the stator.

• A low reading indicates a shorted winding. Replace the

stator.

4. Connect one test lead to a stator power wire. Connect

the other test lead to one of the stator excitation wires.

• A reading of infinity should be measured. If a reading of

infinity is measured and the stator resistance is within

specifications, the stator is functioning properly.

• A reading other than infinity indicates a power winding

shorted to an excitation winding. Replace the stator.

5. Connect one test lead to an excitation wire. Connect the

other test lead to a proper metal ground.

• A reading of infinity should be measured.

• A reading other than infinity indicates a winding shorted

to ground. Replace the stator.

Check Rotor Resistance

1. Set meter to measure Ohms.

2. Connect one test lead to each rotor slip ring (Figure 11).

The slip rings can be accessed through the area where

the brushes were removed. Polarity does not matter.

Figure 11

NOTICE: Do not connect the test lead terminals. Ensure that

each test lead makes a connection to each slip ring.

3. Measure the rotor resistance. Compare it to the nominal

resistance from the specifications listed in the back of

this manual.

• A reading of infinity or a very high resistance indicates

an open circuit or a partially open condition of the rotor

windings.

• A very low resistance indicates a shorted rotor. Replace

the rotor.

• If resistance is within specifications, proceed to Step 4.

4. Connect one test lead to a proper metal ground on the

engine or alternator and the other test lead to either slip

ring.

• A reading of infinity should be measured. If a reading

of infinity is measured and the rotor resistance is within

specifications, the rotor is functioning properly.

• A reading other than infinity indicates a rotor winding

shorted to the rotor shaft. Replace the rotor.

16 BRIGGSandSTRATTON.COM

Alternator Disassembly

Refer to Figure 12 for part identification and to aid in the

diasassembly of the alternator.

Figure 12

A - Plastic End Cover

B - Rotor Through Bolt

C - Mounting Screws (2) for Brush Holder

D - Rear Bearing Carrier

E - Roll Pin

F - Stator

G - Steel Laminations

H - Alternator Adapter

J - Engine Adapter

K - Mounting Screws (4) for Adapters

L - Stator Bolts (4)

A

B

C D

E

F

G H

L

E

K

J

17

Remove the Stator

Ensure the engine/alternator assembly is set on a sturdy

work surface. Do not set the engine/alternator assembly on

the plastic end cover.

1. Remove the plastic end cover (A, Figure 12).

2. Remove the two mounting screws that secure the

brush holder (C) to the rear bearing carrier. Disconnect

the brush holder and set aside.

3. Remove the four stator bolts (L) that secure the rear

bearing carrier to the alternator.

4. Remove the stator assembly. You may need to tap

lightly on the stator assembly with a plastic, dead-blow

hammer to loosen it from the alternator adapter (H).

5. Slide the stator out of the alternator adapter and off the

rotor.

NOTICE: Use care not to damage the windings. Set the stator

on the laminations, not on the coils of the wire.

Remove the Rotor

1. Remove the four screws (D) that secure the alternator

adapter to the engine adapter (J).

2. Loosen, but do not remove, the rotor through-bolt

(B). The rotor through-bolt will prevent the rotor from

falling during disassembly.

3. While supporting and pulling the rotor with one hand,

strike the rotor assembly, on the steel laminations

with a plastic, dead blow hammer (Figure 13) until it

separates from the engine shaft.

Assemble the Alternator

1. Install the rotor and torque to values listed in

Specifications.

2. With stator harness and lead wires facing away from

the engine, place stator (A, Figure 14) over rotor and

into adapter casting (B). Verify roll pin slot (C), in

stator, lines up with the roll pin (D) in adapter.

3. Use a plastic, dead blow hammer to evenly seat stator

into the adapter casting.

4. Unscrew the through-bolt and carefully slide rotor off

the engine crankshaft.

Except for certain engine repairs, there is no need to remove

the engine adapter from the engine.

Figure 13

Figure 14

B

18 BRIGGSandSTRATTON.COM

4. Pull wires up through rear bearing carrier (A, Figure

15). Set rear bearing carrier on rotor bearing and

stator. Verify second roll pin slot (B) in stator lines up

with roll pin (C) in rear bearing carrier.

5. Using a plastic, dead blow hammer, tap rear bearing

carrier evenly over rotor bearing and stator until it

seats.

NOTICE: Do not use stator bolts to draw assembly together.

Figure 15

9. Once wires are connect, rotate brush set three times to

reduce the slack in the wires (A, Figure 17).

6. Insert stator bolts into each hole around the rear

bearing carrier. Tighten bolts in a criss-cross pattern

until snug, then torque to values listed in Generator

Specifications.

7. Rotate engine flywheel by hand slowly to ensure that

the alternator is not binding.

8. Hold brush set with brushes down and tab

(A, Figure 16) facing you. Attach red #6 wire to negative

terminal (B) on the left. Attach blue #2 wire to positive

terminal (C) on the right.

10. Set brushes down into slot on rear bearing carrier

with tab facing down. Align holes in brush set and rear

bearing carrier and insert screws (B). Torque screws to

values listed in Generator Specifications.

11. Route wires away from all rotating parts, then install

cover.

Figure 17

A

B

Figure 16

A

B

C

19

No Load Voltage 255-273

No Load Frequency (RPM) 62.0 - 62.5 Hertz (3720 - 3750 RPM)

Starting Wattage 8,250 watts

Wattage* 5,500 watts

AC Load Current

at 120 Volts 45.8 Amps

at 240 Volts 22.9 Amps

Phase Single Phase

Rated Frequency 60 Hertz

Displacement 18.61 ci (305 cc)

Spark Plug Gap 0.030 in. (0.76 mm)

Fuel Capacity 7 U.S. gallons (26.5 L)

Oil Capacity 28 Ounces (0.83 Liters)

Resistance Values

Winding Resistance 030430-2

Rotor (at the slip rings) 24.3 - 29.1 Ohm

Power (wires 11-22 & 33-44) 0.19 - 0.24 / 0.19 - 0.24 Ohm

Excitation (wires 2-6) 1.26 - 1.50 Ohm

Power Ratings: The gross power rating for individual gas engine models is labeled in accordance with SAE (Society of

Automotive Engineers) code J1940 (Small Engine Power & Torque Rating Procedure), and rating performance has been

obtained and corrected in accordance with SAE J1995 (Revision 2002-05). Torque values are derived at 3060 RPM; horsepower

values are derived at 3600 RPM. Actual gross engine power will be lower and is affected by, among other things, ambient

operating conditions and engine-to-engine variability. Given both the wide array of products on which engines are placed and

the variety of environmental issues applicable to operating the equipment, the gas engine will not develop the rated gross power

when used in a given piece of power equipment (actual "on-site" or net power). This difference is due to a variety of factors

including, but not limited to, accessories (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.), application

limitations, ambient operating conditions (temperature, humidity, altitude), and engine-to-engine variability. Due to

manufacturing and capacity limitations, Briggs & Stratton may substitute an engine of higher rated power for this Series engine.

* This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and

generators).

Fastener Torque Values

Engine Adapter to Engine 200 lb-in. (23 Nm)

Alternator Adapter to Engine Adapter 200 lb-in. (23 Nm)

Rotor Bolt to Crankshaft 200 lb-in. (23 Nm)

Brushes to Rear Bearing Carrier 50 lb-in. (7 Nm)

Stator Bolt 80 lb-in. (9 Nm)

Generator Specifications

20 BRIGGSandSTRATTON.COM

Generator Wiring Diagram

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