Briggs & Stratton 273521, 271172, 270962, CE8069, 276535 manual Tri-CircuitAlternator, Test Diode

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Tri-Circuit Alternator

2

Figure 21

6.With the engine running at 3600 RPM, output should be between 2 - 4 Amps DC.

NOTE: The output will vary with the battery voltage. At maximum battery voltage the output will be approximately 2 Amps.

7. If NO or LOW output is found, test diode.

Test Diode

In the Diode Test position, the meter will display forward voltage drop across the diode(s). If voltage drop is less than 0.7 volts, meter will “Beep” once as well as display voltage drop. A continuous tone indicates continuity (shorted diode). An incomplete circuit (open diode) will be displayed as “OL.”

1.Insert RED test lead (A, Figure 22) into the V Ω receptacle and set the rotary switch to Diode position.

2.Insert BLACK test lead (B) into the COM receptacle in the meter.

3.Attach RED test lead clip to point (C) and Black test lead clip to point (D). (It may be necessary to pierce wire with a pin as shown.)

Figure 22

•If meter “Beeps” once, diode is OK.

•If meter makes a continuous tone, diode is defective (shorted).

•If meter displays “OL,” proceed to Step 4.

4.Reverse test leads.

•If meter “Beeps” once, diode is installed backwards.

•If meter still displays “OL,” diode is defective (open).

5.If diode tests OK, replace stator.

NOTE: Service replacement diode harnesses are available. Use Rosin Core solder when installing new harness. Use shrink tubing or tape for all connections. Do not use crimp connectors.

Tri-Circuit Alternator

The tri-circuit alternator provides alternating current (AC) through a single output lead and connector to a wiring harness containing two diodes.

One diode rectifies the AC current to 5 Amps negative (-) DC for lights. The second diode rectifies the AC current to 5 Amps positive (+) DC for battery charging and external loads, such as an electric clutch.

NOTE: Some original equipment manufacturers (OEMs) supply diodes as an integral part of the equipment wiring harness. Some OEMs use a 1 Ohm-20 Watt resistor placed in series with (+)

DC charging lead, limiting the charging current to approximately 3 Amps when the clutch is not engaged. When the clutch is engaged, the

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Contents Repair Manuals for other Briggs & ledooStrattonQuality Starts With A Master Service Technician Single Cylinder OHV Air-CooledEnginesFORWARD Copyright 2009 Briggs & Stratton CorporationAll rights reserved Engine Models This Engine Repair Manual includes the following1 2 3 4 5 6 7 8 9 10 11 12 SECTION 1 - Safety, Maintenance and AdjustmentsSECTION 2 - Troubleshooting Page SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS ENGINE SAFETY Signal Words in Safety MessagesHazard Symbols and Meanings When testing for spark Before performing adjustments or repairsExplosion and fire could result BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM BRIGGS & STRATTON MODEL NUMBERING SYSTEMYOUR KEY TO THE WORLD’S FINEST ENGINES High Altitude ENGINE MAINTENANCEFuel and Oil Recommendations Fuel must meet these requirementsEvery 50 Hours or Annually Maintenance Chart First 5 HoursEvery 8 Hours or Daily Every 25 Hours or AnnuallyAssemble Flywheel Brake Inspect Brake and SwitchesAir Filter Combustion ChamberFigure Figure Figure Figure Figure FigureInspection InstallSnow Hood RemoveNOTICE Oil and Oil FilterSpark Plug NOTICECooling System Horizontal Models 110000, 120000, ENGINE ADJUSTMENTSRemote Controls Remote Control Wire Travel2.Move throttle lever to fast position Governor Adjustments Static AdjustmentTop No Load Adjustment Vertical Models 97700, 2.Place throttle in FAST position Final Adjustment All Models Initial Adjustment All ModelsAdjust Valve Clearance Vertical Models 110000, 120000 Early Production SECTION 2 - TROUBLESHOOTING OIL GARD SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE WILL NOT START - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE STARTS AND RUNS WITH LOW OIL Engine Running SYSTEMS CHECK1 Check Ignition Engine StoppedSolenoid Plunger Test Testing Fuel Shut Off SolenoidSolenoid Wiring Test 2 Check CarburetionPossible Causes for Poor Compression 3 Check CompressionDC Shunt ELECTRICAL SYSTEMSEquipment Used for Testing Digital MultimeterAlternator System Diagnosis ComplaintPossible Causes Alternator Identification 4.Dual Circuit Figure 1.0.5 Amp DC Only Figure2.14 Volt AC Only Figure 3.3 Amp DC Only Figure6.5/9 Amp DC Figure 7.10/16 Amp DC Figure8.20 Amp DC Figure 3-AmpDC Only Alternator Testing Alternator OutputFlywheel Identification 5 Amp DC Only AlternatorTest Diode 14-VoltAC AlternatorTest Alternator Output-DC Dual Circuit AlternatorTest Alternator Output Test Alternator Output-ACTest Diode Tri-CircuitAlternatorTest Diode Charging Circuit Test RED WireLighting Circuit Test WHITE Wire Test Alternator Output5 & 9 Amp DC Regulated Alternator Test Alternator OutputTest Regulator-Rectifier Test Regulator - Rectifier 10 & 16 Amp DC Regulated AlternatorTest Alternator Output receptacle2.Install shunt to negative -battery terminal Test Alternator Output DC Output Charging Wire Test20 Amp DC Regulated Alternator NOTICE5.Rotate selector to DC volts position FigureELECTRIC STARTERS SYSTEM 3, SYSTEMModel Series 97700, 99700, 110000, Test Starter Motor Test Interlock SwitchTest Interlock Switch Wiring 12 Volt DC Starter MotorTest Starter Motor 120-VoltAC Starter Motor Model Series 120000, 150000, 200000,Test Solenoid Charging Battery BATTERIESBattery and Cable Recommendations Battery InstallationTesting Battery Engine Won’t Stop EQUIPMENT AFFECTING ENGINE OPERATIONOIL GARD SYSTEMS Hard Starting or Will Not StartEngine Starts and Runs With Low Oil On/Off Switch Light Does Not FlashSECTION 3 - EXHAUST SYSTEMS Remove Guard and Muffler MUFFLER SERVICESpark Arresters Horizontal Models 110000, 120000,Never reinstall broken or damaged components Install Muffler and GuardInspect Exhaust System 3.Remove muffler support screws A, Figure Horizontal Models 200000,Shown is a typical muffler application Figure Remove Guard and MufflerAll exhaust system components must be inspected whenever the exhaust system is disassembled. Check muffler mounting bracket and/or muffler adapters for cracked welds or breakage. Check muffler for split seams, loose internal parts, or cracked welds. Replace any damaged parts with new OEM parts Never reinstall broken or damaged componentsInstall Muffler and Guard Inspect Exhaust SystemInspect Exhaust System Never reinstall broken or damaged componentsInstall Muffler and Guard Vertical Models 97700, 99700, 110000,components Never reinstall broken or damagedInstall Muffler and Guard Inspect Exhaust SystemNever reinstall broken or damaged components Remove MufflerInspect Exhaust System Install Muffler Remove Muffler Never reinstall broken or damaged componentsInstall Muffler Shown is a typical muffler application FigureSECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS Inspection InstallationFuel Pump RemovalRemoval Fuel FilterFuel Tanks and Shut-offValves Horizontal Models 110000, 120000, 150000, 200000,Vertical Model InstallationInstallation Vertical Models 97700, 99700, 110000,Installation Inspection2.Inspect fuel tank for •Corrosion •Leaks Carburetor Identification CARBURETIONCarburetor Service LMS Carburetor Vertical Models 97700, 99700, 110000,Remove Carburetor Disassemble Carburetor Assemble Carburetor Inspect and Clean Carburetor ComponentsInstall Carburetor Remove Carburetor LMS Carburetor Horizontal Models 110000, 120000,Assemble Carburetor Inspect and Clean Carburetor ComponentsDisassemble Carburetor •Passages in the fixed main jet bowl nutedge of the plug with a non-hardeningsealant Install Carburetor ReadyStart Carburetor Vertical ModelRemove Carburetor Inspect and Clean Carburetor Disassemble CarburetorAssemble Carburetor LMT Carburetor Remove Carburetor 3.Move clamp and disconnect hose from carburetorDisassemble Carburetor Assemble Carburetor Inspect and Clean CarburetorPage bracket.4 Install CarburetorNikki Carburetor Vertical Models 280000, 310000, Remove CarburetorDisassemble Carburetor 11.Remove the main jet and seal Inspect and Clean CarburetorAssemble Carburetor •Choke shaft and choke valveInstall Carburetor 12.Install new o-ringon fuel transfer tube EVertical Model 310000 Gaseous Fuel Nikki LP/NG MixerSECTION 5 - GOVERNOR SYSTEMS Linkage and Spring Orientation GOVERNOR SYSTEMSDisassemble Governor ServiceGoverned RPM Limits Horizontal Models 110000, 120000, 150000, 200000,Assemble Inspect GovernorDisassemble Inspect GovernorAssemble Governor 8. Adjust governor system per Section SECTION 6 - CYLINDER HEAD AND VALVES Remove Cylinder Head CYLINDER HEADS AND VALVESInspection Disassemble Cylinder HeadAssemble Cylinder Head Install Cylinder Head NOTE: Do not torque each screw in one step as it may result in a warped cylinder head. Step- torque all screws to approximately 1/3 of final torque value, then to 2/3 final torque value, then finish at final torque value Inspection Remove Cylinder HeadModels 200000, 210000, 280000, 310000, Disassemble Cylinder Headmm or more, replace the entire head. If plug gauge is not available, see Section 12 - Engine Specifications for the valve guide reject dimension Install Cylinder HeadAssemble Cylinder Head 4.Install push rods through guides and into same positions as removed. Ensure rods are seated in valve tappets. Place valve stem caps if used on valve stems Figure Page SECTION 7 - STARTERS Vertical Models 97700, REWIND STARTERSRemove Blower Housing / Rewind Starter Horizontal Models 110000, 120000, 150000, 200000,Vertical Models 110000, Service Rewind Starter Vertical ModelDisassemble Rewind Starter Assemble Rewind Starter Inspect Rewind Starter Parts2.Install the oil fill tube and dipstick C Vertical Models 97700,Vertical Models 110000, Inspect Clutch Parts Service Starter ClutchVertical Model Disassemble Starter ClutchCheck Starter Drive and Clutch ELECTRIC STARTERSReplace Ring Gear System 3, SystemCheck Starter Drive and Clutch Install Starter Drive and Clutch12 Volt Starters Remove Starter Drive and ClutchAssemble Starter Motor Drive - C-Ring Retainer Disassemble Starter Drive - Roll Pin Retainer Assemble Starter Drive - Roll Pin Retainer 120-VoltStartersSECTION 8 - LUBRICATION SYSTEMS Horizontal Models 110000, 120000, EXTENDED OIL FILL AND DIPSTICKBREATHERS Install BreatherRemove Breather 3.Inspect oil drain-backholes C, Figure 3 to make sure they are open. Clean as neededInstall Breather Check BreatherCheck Breather Install Breather8Current Production Remove BreatherOil Slinger Lubrication LUBRICATION SYSTEMSInstall Breather Oil Dipper LubricationVertical Models 120000, 210000, 280000, 310000, Oil Pump ServiceOil Slinger with Pressure Filtration Pressure LubricationRemove Pump Screen Install Screen and Gerotor Pump Inspect Oil Pump PartsOil Filter and Adapters Remove Oil Gard Systems Oil Pressure SwitchInstall Test Oil Pressure SwitchIdentification Lead Wire ColorsLead Wire Colors TroubleshootingSECTION 9 - CYLINDERS, COVERS AND SUMPS Resizing Bore CYLINDERInspect Cylinder Reconditioning BoreCheck Plain Bearings MAIN BEARINGSCleaning Cylinder Check BearingsPTO Bearing Tools Replace BearingsReplace DU Bearings Magneto Bearing ToolsReplace Ball Bearing Horizontal Models 120000, Tool/Part Bearing Installation ToolsReplace Ball Bearing Horizontal Models 200000, Bearing Removal ToolsReplace Ball Bearing All Vertical Models Installation COVERS AND SUMPSFigure Figure FigurePage SYSTEMS, AND GEAR REDUCTIONS SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCINGCheck Crankshaft CRANKSHAFTS AND CAMSHAFTSRemove Crankshaft and Camshaft InspectInstall Crankshaft and Camshaft Install Crankcase Cover or Sump Check and Adjust Crankshaft End Play Inspect Gear Reduction Parts GEAR REDUCTIONDisassemble Gear Reduction Assemble Gear ReductionFill Gear Case with Lubricant Assemble Auxiliary PTO Drive Shaft AUXILIARY PTOInspection Remove Auxiliary PTO Drive ShaftRemove Counterbalance System COUNTERBALANCE SYSTEMSSynchro-BalanceSystem DisassembleAssemble InstallDisassemble InstallAVS Balance System RemovePage SECTION 11 - PISTONS, RINGS AND CONNECTING RODS Inspect PISTONS, RINGS, & CONNECTING RODSRemove Piston and Connecting Rod DisassembleCheck Connecting Rod AssembleCheck Ring End Gap Install Piston and Connecting Rod SECTION 12 - ENGINE SPECIFICATIONS TORQUE MODEL 110000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSREJECT DIMENSIONS TORQUE MODEL 120000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSMain Bearing TORQUE MODEL 150000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSREJECT DIMENSIONS TORQUE MODEL 200000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSMain Bearing TORQUE MODEL 210000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSMain Bearing TORQUE MODELS 97700 & 99700 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSREJECT DIMENSIONS TORQUE MODEL 110000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSREJECT DIMENSIONS TORQUE MODEL 120000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSREJECT DIMENSIONS TORQUE MODEL 210000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSREJECT DIMENSIONS TORQUE MODEL 280000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSMain Bearing TORQUE MODEL 310000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSMain Bearing TORQUE MODEL 330000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONSMain Bearing

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