POWERSMART SERIES™ INVERTER GENERATOR SERVICE AND REPAIR MANUAL N o fo t R r ep ro du ct io n MODEL 030473 This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators) 279957GS Rev.
n N o fo t R r ep ro du ct io 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. 2 BRIGGSandSTRATTON.
Table of Contents Important Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . 4 Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rewind Starter Replacement . . . . . . . . .
Important Safety Instructions SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. Safety Symbols and Meanings Kickback Electrical Shock Fire Explosion Read Manual Moving Parts Flying Objects Chemical Burn N o fo t R r ep ro du ct io Explosive Pressure Hot Surface WARNING Running engine gives off carbon monoxide, an odorless, colorless, poison gas.
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. • • • • • • WARNING Exhaust heat/gases could ignite combustibles or structures 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.
When Adjusting Or Making Repairs To Your Generator • Disconnect the spark pluh wire from the spark plug and place the wire where is 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. NOTICE Improper treatment of generator could damage it and shorten its life.
Fuel Recommendations Generator Location WARNING Exhaust heat/gases could ignite combustibles or structures resulting in death, serious injury and/or property damage. • Keep at least 5 feet (152 cm) of clearance on all sides of generator including overhead. For proper clearance and air movement, place generator outdoors in an area that will not accumulate deadly exhaust gas.
Fuel Tank Cap Vent Lever The fuel tank cap is provided with a vent lever (A, Figure 2) to seal the fuel tank. The vent lever must be in the “ON” position for the engine to run. Grounding Fastener The generator neutral is floating, which means that the AC stator winding is isolated from the grounding fastener and the AC receptacle ground pins. Therefore, the AC receptacle ground pins are not functional and electrical devices, such as a GFCI will not operate.
Generator Components A B C R D P E F n N H J N o fo t R r ep ro du ct io G A - Fuel Tank Cap Vent Lever — Turn the vent lever to the “ON” position when operating the generator. Turn to the “OFF” position when not in use. B - Fuel Tank — Capacity of 1.0 U.S. gallon (3.7L). C - Choke Lever — Used when starting cold engine. D - Side Maintenance Cover — Remove to gain access for air cleaner and oil service. E - Recoil Starter — Used to start the engine manually.
Maintenance Generator Maintenance Maintenance Schedule Follow the hourly or calendar interval, whichever occurs first. More frequent service is required when operating in adverse conditions noted below. Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean and dry environment where it will not be exposed to excessive dust, dirt, moisture, or any corrosive vapors.
Engine Maintenance WARNING Unintentional sparking could cause fire or electric shock resulting in death or serious injury. When Adjusting Or Making Repairs To The Generator • Disconnect the spark plug wire from the spark plug and place the wire where is cannot contact spark plug. When Testing For Engine Spark • Use approved spark plug tester • DO NOT check for spark with spark plug removed. Checking Oil Level / Adding Oil Oil level should be checked prior to each use or at least every 8 hours of operation.
Changing Engine Oil If the generator is used under extremely dirty or dusty conditions, or in extremely hot weather, change the oil more often. Service Air Cleaner The engine will not run properly and may be damaged if it is run with a dirty air cleaner. Service more often if operating under dirty or dusty conditions. CAUTION Avoid prolonged or repeated skin contact with used motor oil. • Used motor oil has been shown to cause skin cancer in certain laboratory animals.
Service Spark Plug 1. Loosen the four handle screws and remove the handle (Figure 8). 4. 5. Remove spark plug and inspect for pitting, corosion, cracks, or other signs of damage. Check electrode gap with wire feeler gauge (A, Figure 10) and reset the spark plug gap to recommended gap if necessary. Figure 8 Figure 10 6. 7. 8. 9. Figure 9 Replace spark plug if electrodes are pitted, burned, or porcelain is cracked. Use the recommended replacement plug. Install spark plug and torque to 180 in. lbs.
• • • Remove screw (Figure 12) that attaches spark arrester screen muffler. Remove spark arrester screen. Figure 12 3. 4. Inspect screen and obtain a replacement if torn, perforated, or otherwise damaged. DO NOT use a defective screen. If screen is not damaged, clean it with a brush. Reattach screen to muffler. Reattach muffler guard. N o fo t R r ep ro du ct io • • • WARNING Exhaust heat/gases could ignite combustibles or structures resulting in death, serious injury and/or property damage.
Rewind Starter Replacement Disassemble Rewind Starter 1. Remove control panel, inverter, and fuel tank as described in the Troubleshooting section. 2. Locate the rewind starter handle (A, Figure 13) and remove the screw that is located under the handle. 4. 5. 6. 7. 8. A Pull out rope from rewind starter as far as it will go. Then allow rope to retract slightly until the hole in the pulley and eyelet in the housing are lined up.
Figure 15 n Assemble Rewind Starter 1. Install pulley and spring assembly into starter housing. Rotate pulley clockwise until slight resistance is felt, which indicates that the spring has engaged in the anchor tab. 2. Install pawl springs and pawls. Position retainer plate on pulley. Ensure that the slots in the retainer fit over the tabs in the pulley, then install shoulder screw. Torque screw to 30 in. lb. (3 Nm). 3. While holding retainer, rotate the pulley to extend and retract the pawls.
Troubleshooting Fuel System Fuel Pump The fuel pump (A, Figure 16) is located on inside of cover. It is operated by vacuum pulses from the engine. The fuel pump is not serviceable. If the pump does not operate after inspection, replace the pump. Inspect pump for: • Ensure vacuum hose is connected properly • Restrictions or leaks in vacuum or fuel hoses • Cracks or distortion in pump body or base Fuel Tank The fuel tank is metal (A, Figure 17) and is not repairable.
Fuel Valve The fuel valve is mounted behind the side maintenance cover. 3. Check the fuel valve for leaks (C, Figure 21). Check the valve for proper operation as follows: 1. Using small, flat-head screwdriver, pry off cover to the fuel valve knob (Figure 19). C Figure 21 If the fuel valve leaks, it must be replaced as follows: 1. Loosen four screws (Figure 22) on the control panel. 2. N o fo t R r ep ro du ct io n Figure 19 Remove screw under the cover to remove the knob (B, Figure 20).
2. 3. Remove control panel from enclosure and, without disconnecting wiring, set control panel aside (D, Figure 23). Remove inverter from enclosure (E) and, without disconnecting wiring, set inverter assembly aside. 5. 6. 7. Locate fuel valve (F, Figure 25) inside of the generator enclosure. Remove hoses (G) and loosen screw (H) to remove the fuel valve. Install a new fuel valve using the above steps in reverse order. E H F G D Figure 23 Close vent on fuel cap.
Carburetor Inspect carburetor for: • Blockage • Leaks • Varnish or Gummy Residue If carburetor is suspected to have a fuel leak or blockage, follow these steps: 1. Loosen the two self-locking screws and remove the side maintenance cover (Figure 26) and set aside. This will expose the air filter and carburetor assemblies. 3. Remove screw from air filter cover (Figure 28). Set cover aside. Figure 28 Remove breather filter (B, Figure 29) to expose the air cleaner assembly screw.
5. Remove air cleaner assembly and set aside (Figure 30). 8. 9. While leaving the stepper motor attached, carefully slide carburetor assembly off engine. Remove bowl nut (Figure 33) and the fuel bowl. Check for damage, leaks, and gummy residue. Figure 30 Inspect carburetor overload hose (D, Figure 31).If there is fuel leaking from this hose, the fuel inlet could be blocked and will require cleaning. Figure 33 10. Remove the float hinge pin (Figure 34). N o fo t R r ep ro du ct io n 6.
11. Ensure the inlet needle and spring (A) are assembled correctly, with the spring located below the float bosses (Figure 35). 14. Inspect openings in the carburetor body for blockage. Inspect throttle and choke shafts for wear or damage. If found, replace the entire carburetor assembly. 15. Inspect all valves, openings, and o-rings for damage or wear. If damage is found, replace the carburetor. 16. Assemble carburetor using steps 8 through 12 in reverse order. A N o fo t R r ep ro du ct io 12.
Stepper Motor The stepper motor (electric throttle actuator) responds to the inverter module to continuously match engine speed to the power needs of the generator. The stepper motor (Figure 37) is attached to the top of the carburetor assembly. 2. 3. 4. 5. Measure the resistance across wires (B, Figure 39). Measure the resistance across wires (C, Figure 39). Resistance should measure between 45 - 55 Ω. If the resistance measured is outside of this specified range, replace the stepper motor.
2. 3. Remove two screws that hold the stepper motor to the carburetor assembly (F, Figure 41). Locate the throttle lever (G). 4. 5. NOTE: When removing the stepper motor from the carburetor assembly, the spring (H) may become disengaged. Ensure that the spring does not become lost. Actuate the throttle lever to check for proper movement (Figure 42). The lever should move freely in both directions. If the linkages stick, spray lubricant on the lever and manually move the lever.
Engine Will Not Start The Engine Cranks But Has No Spark If the engine cranks but has no spark, it could be the micro switch (A, Figure 43). 3. Turn the microswitch on and test between the terminal (A, Figure 45) and ground. A A Figure 45 • Test the continuity of the microswitch as follows: 1. Remove the control panel. 2. Disconnect the 10-pin connector (Figure 44) that is connected to the ignition module (module with three LED lights).
Low Oil Switch The low oil indicator system is designed to prevent engine damage caused from insufficient engine oil. If the engine oil level drops below a preset level, the yellow LED low oil indicator light (Figure 47) illuminates and an oil switch will stop the engine. 4. Test for continuity between ground and the low oil switch (A, Figure 49). • If continuity is not measured, the switch is good. • If continuity is measured and the oil level is good, either the switch or the wiring is defective.
Ignition Spark Circuit When the engine is running the 27V coil produces a voltage that is present at the ignition module. When the magnet on the flywheel (rotor) passes by the trigger coil, this trigger voltage is sensed by the ignition module. When the ignition module senses this trigger voltage, the module sends the voltage from the 27V coil in a pulse to the ignition coil. The ignition coil then creates a spark at the spark plug. 4. 5. Disconnect ignition winding.
3. Measure the resistance between the trigger coil (A, Figure 54) and ground. Test Ignition Coil 1. Locate the connector for the ignition coil (A, Figure 56) and disconnect.. A A Figure 54 4. Figure 56 2. Attach meter test leads to primary side of the ignition coil and measure the resistance (B, Figure 57). n If 80-130 Ω resistance is measured the coil is good. If resistance is not to specifications, check wire connections and retest. • If resisitance is still not to specifications, replace coil.
3. Attach one test lead to either terminal of ignition coil connector and the other lead to the spark plug cap (Figure 58) to measure the secondary resistance. Ignition Module There is no test for the ignition module. If all ignition winding tests are correct, the ignition module is faulty. Replace the ignition module. No AC Output 1. Check the output indicator (A, Figure 60). If the green LED is illuminated, check the plug connection and check for loose wires.
3. 5. Measure for 120 VAC ouput (C, Figure 62). Then measure resistance across sub-windings (E, Figure 64). E C Figure 62 Figure 64 • • • • • 4. Disconnect the main winding connector and measure resistance across the windings (D, Figure 63). If resistance is 0.15 - 0.30 Ω the windings are good. If resistance is not to specifications, check wire connections, or repair/replace wires, then retest. If resistance is still not to specifications, replace the stator winding.
2. Disassemble panel cover to locate and check the wire connections (A, Figure 66). 3. Locate battery winding connector (B, Figure 67) and mesure resistance across the terminals (C). A B A Figure 66 n • Repair and/or replace any loose wire connections and retest. If DC ouput is still not measured, proceed to Step 3. N o fo t R r ep ro du ct io • C Figure 67 • • • If resistance is 0.3 - 0.7 Ω the winding is good.
Generator Specifications Starting Wattage Wattage* Load Current at 120 Volts AC at 12 Volts DC Rated Frequency Phase Displacement Spark Plug Gap Intake Valve Clearance Exhaust Valve Clearance 13.3 Amps 5 Amps 60 Hertz Single Phase 6.44 cu. in. (105.6 cc) .025 in. (.65 mm) .003 - .005 in. (.08 - .13 mm) cold .005 - .007 in. (.13 - .18 mm) cold 1.0 U.S. gallon (3.7 L) 13.5 Ounces (0.
N o fo t R r ep ro du ct io n Generator Wiring Diagram 33
n N o fo t R r ep ro du ct io
