Simplicity 030430 User manual

Category
Power generators
Type
User manual

This manual is also suitable for

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
Copyright © 2010. All rights reserved. No part of this material
may be reproduced or transmitted in any form without the express
written permission of Briggs & Stratton Power Products Group, LLC.
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
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
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
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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Simplicity 030430 User manual

Category
Power generators
Type
User manual
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