Briggs & Stratton 276535, 271172, 270962, CE8069, 273521 Install shunt to negative -battery terminal

Page 43

2.Install shunt to negative (-) battery terminal.

2

NOTICE: Connect test leads BEFORE starting the engine. Be sure connections are secure. If a test lead vibrates loose while engine is running, the regulator-rectifier may be damaged.

Use the DC Shunt #19468 (D, Figure 29) to avoid blowing the fuse in the test meter when testing the DC output of the 16 Amp system. The DC Shunt must be installed to the negative (-) terminal of the battery. All connections must be clean and tight to obtain accurate readings.

1.Connect stator wire harness to regulator- rectifier.

2.Install shunt to negative (-) battery terminal.

3.Insert RED test lead (A) into V Ω receptacle in meter. Connect to RED post terminal (C) on shunt.

4.Insert BLACK test lead (B) into COM receptacle in meter and connect to BLACK post terminal (E) on shunt.

5.Rotate selector to 300mV position.

and all connections are clean and secure. If there is still NO or LOW output, replace the regulator-rectifier.

Regulator-Rectifier with Charge Indicator The regulator-rectifier #493219 is used by OEMs that have a charging indicator light instead of an ammeter. In addition to the RED DC output wire (A, Figure 30), the regulator-rectifier has a blue wire (B) to activate a charging indicator light when battery voltage is below 12 volts. The connector has a raised rib (C) on the red wire side to indicate the output side of the connector.

Figure 29

6.Run the engine at 3600 RPM. The output should be:

•3-10 Amps - 10 Amp System

•3-16 Amps - 16 Amp System

NOTE: The amperage produced depends on the battery voltage. If the battery is below 11 Volts, the output reading would be 10 or 16 Amps, depending upon the alternator system being tested. The amperage will be less at maximum battery voltage.

7.If NO or LOW output is found, be sure that the regulator-rectifier is grounded properly

Figure 30

The charging indicator light should light when the key switch in ON and the engine not running. With the engine running, the charging indicator light should go out, indicating that the charging circuit is operating and the battery voltage in above 12 volts.

The charge indicator light and wiring is supplied by the OEM.

DC charging output values and test procedures are the same as those listed for the 10 amp and 16 amp systems.

40

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Contents Repair Manuals for other Briggs & ledooStrattonQuality Starts With A Master Service Technician Single Cylinder OHV Air-CooledEnginesCopyright 2009 Briggs & Stratton Corporation FORWARDAll rights reserved Engine Models This Engine Repair Manual includes the followingSECTION 1 - Safety, Maintenance and Adjustments 1 2 3 4 5 6 7 8 9 10 11 12SECTION 2 - Troubleshooting Page SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS Signal Words in Safety Messages ENGINE SAFETYHazard Symbols and Meanings When testing for spark Before performing adjustments or repairsExplosion and fire could result BRIGGS & STRATTON MODEL NUMBERING SYSTEM BRIGGS & STRATTON NUMERICAL IDENTIFICATION 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 Static Adjustment Governor AdjustmentsTop 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 MultimeterComplaint Alternator System DiagnosisPossible Causes Alternator Identification 4.Dual Circuit Figure 1.0.5 Amp DC Only Figure2.14 Volt AC Only Figure 3.3 Amp DC Only Figure7.10/16 Amp DC Figure 6.5/9 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 OutputTest Alternator Output 5 & 9 Amp DC Regulated AlternatorTest 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 FigureSYSTEM 3, SYSTEM ELECTRIC STARTERSModel Series 97700, 99700, 110000, Test Starter Motor Test Interlock Switch12 Volt DC Starter Motor Test Interlock Switch WiringTest Starter Motor Model Series 120000, 150000, 200000, 120-VoltAC Starter MotorTest 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,Install Muffler and Guard Never reinstall broken or damaged componentsInspect 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 SystemRemove Muffler Never reinstall broken or damaged componentsInspect 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,Inspection Installation2.Inspect fuel tank for •Corrosion •Leaks Carburetor Identification CARBURETIONVertical Models 97700, 99700, 110000, Carburetor Service LMS CarburetorRemove 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 ReadyStart Carburetor Vertical Model Install CarburetorRemove Carburetor Disassemble Carburetor Inspect and Clean CarburetorAssemble Carburetor LMT Carburetor 3.Move clamp and disconnect hose from carburetor Remove CarburetorDisassemble Carburetor Assemble Carburetor Inspect and Clean CarburetorPage bracket.4 Install CarburetorRemove Carburetor Nikki Carburetor Vertical Models 280000, 310000,Disassemble 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 GovernorInspect Governor DisassembleAssemble 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 HeadInstall Cylinder Head mm or more, replace the entire head. If plug gauge is not available, see Section 12 - Engine Specifications for the valve guide reject dimensionAssemble 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, Vertical Model Service Rewind StarterDisassemble Rewind Starter Assemble Rewind Starter Inspect Rewind Starter PartsVertical Models 97700, 2.Install the oil fill tube and dipstick CVertical 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 Inspect Oil Pump Parts Install Screen and Gerotor PumpOil 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 DisassembleAssemble Check Connecting RodCheck 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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