Briggs & Stratton CE8069, 271172, 270962, 276535, 273521 Test Starter Motor, Test Interlock Switch

Page 47
Test Starter Motor

2

Figure 34

If the pinion gear sticks, clean the helix and gear with a mild solvent and compressed air. If the pinion continues to stick, replace the entire starter drive assembly.

NOTE: Do not oil the pinion gear or helix.

The starter motor clutch is designed to prevent damage from shock loads such as engine backfire. If clutch slips while cranking, replace the entire starter drive assembly.

Test Starter Motor

1.Clamp starter motor test fixture in vise.

2.Remove starter motor from engine and mount to fixture (Figure 35).

NOTICE: Do not clamp motor housing in a vise or strike with a hammer. Most starter motors contain ceramic magnets that can be damaged if the motor housing is hit, deformed, or dented.

3.Set meter to DC Amps position. Connect the black test lead (C), red test lead (D), starter motor, battery (E), and meter as shown in Figure 35.

Figure 35

4.Using Tachometer #19200 (F), spin the starter motor and note RPMs and amperage draw. A starter motor in good condition will be:

1400 RPM (minimum)

9 Amps (maximum)

If starter motor is not within specifications, it must be replaced.

Test Interlock Switch

1.Disconnect interlock switch wires from spade terminals on switch.

2.Set meter to Ohms position.

3.Connect meter test leads to two spade terminals of switch (Figure 36). Meter should read no continuity. If switch fails, replace the switch. Push switch lever in until it clicks. Meter should read low resistance. If switch fails, replace the switch.

Figure 36

44

Image 47
Contents Repair Manuals for other Briggs & ledooStrattonQuality Starts With A Master Service Technician Single Cylinder OHV Air-CooledEnginesAll rights reserved FORWARDCopyright 2009 Briggs & Stratton Corporation Engine Models This Engine Repair Manual includes the followingSECTION 2 - Troubleshooting 1 2 3 4 5 6 7 8 9 10 11 12SECTION 1 - Safety, Maintenance and Adjustments Page SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS Hazard Symbols and Meanings ENGINE SAFETYSignal Words in Safety Messages When testing for spark Before performing adjustments or repairsExplosion and fire could result YOUR KEY TO THE WORLD’S FINEST ENGINES BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEMBRIGGS & STRATTON MODEL NUMBERING SYSTEM 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 Top No Load Adjustment Vertical Models 97700, Governor AdjustmentsStatic Adjustment 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 MultimeterPossible Causes Alternator System DiagnosisComplaint Alternator Identification 4.Dual Circuit Figure 1.0.5 Amp DC Only Figure2.14 Volt AC Only Figure 3.3 Amp DC Only Figure8.20 Amp DC Figure 6.5/9 Amp DC Figure7.10/16 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 Regulator-Rectifier 5 & 9 Amp DC Regulated AlternatorTest Alternator Output 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 FigureModel Series 97700, 99700, 110000, ELECTRIC STARTERSSYSTEM 3, SYSTEM Test Starter Motor Test Interlock SwitchTest Starter Motor Test Interlock Switch Wiring12 Volt DC Starter Motor Test Solenoid 120-VoltAC Starter MotorModel Series 120000, 150000, 200000, 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,Inspect Exhaust System Never reinstall broken or damaged componentsInstall Muffler and Guard 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 SystemInspect Exhaust System Never reinstall broken or damaged componentsRemove Muffler 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, 110000,2.Inspect fuel tank for •Corrosion •Leaks InstallationInspection Carburetor Identification CARBURETIONRemove Carburetor Carburetor Service LMS CarburetorVertical Models 97700, 99700, 110000, 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 Remove Carburetor Install CarburetorReadyStart Carburetor Vertical Model Assemble Carburetor Inspect and Clean CarburetorDisassemble Carburetor LMT Carburetor Disassemble Carburetor Remove Carburetor3.Move clamp and disconnect hose from carburetor Assemble Carburetor Inspect and Clean CarburetorPage bracket.4 Install CarburetorDisassemble Carburetor Nikki Carburetor Vertical Models 280000, 310000,Remove 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 GovernorAssemble Governor DisassembleInspect 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 HeadAssemble 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 dimensionInstall 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, Disassemble Rewind Starter Service Rewind StarterVertical Model Assemble Rewind Starter Inspect Rewind Starter PartsVertical Models 110000, 2.Install the oil fill tube and dipstick CVertical Models 97700, 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 Oil Filter and Adapters Remove Install Screen and Gerotor PumpInspect Oil Pump Parts 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 Ring End Gap Check Connecting RodAssemble 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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