Alternator System Diagnosis, Complaint | Briggs & Stratton CE8069

Alternator System Diagnosis

	Complaint	Possible Causes
	Battery Not	• Engine RPM too low.
	Charging	• Engine RPM too low.
		• Inline fuse “blown” (if equipped)
		• Defective or damaged battery (shortened battery cells)
		• Loose, pinched, or corroded battery ground leads or charge
		leads
		• Open, shorted, or grounded wires between output
		connector and battery
		• Defective diode (open or shorted)
		• Diode installed incorrectly (reversed)
		• Defective or improperly grounded regulator-rectifier
		• Excessive current draw from accessories
		• Weak or damaged alternator magnets

	Battery	• Severe battery vibration (missing or broken tie-down
	Overcharged	• Severe battery vibration (missing or broken tie-down
		straps)
		• Battery rate of charge not matched to alternator output
		• Damaged battery (shorted battery cells)
		• Defective regulator
		• 1-Ohm resistor shorted or grounded (Tri-Circuit system
		only)

	Headlamps Not	• Inline fuse “blown” (if equipped)
	Working	• Inline fuse “blown” (if equipped)
		• Defective headlamps
		• Loose or corroded wires
		• Open, shorted, or grounded wires between output
		connector and electric clutch
		• Light switch defective
		• Defective diode Tri-Circuit system (open or shorted – white
		output lead side).
		• Weak or damaged alternator magnets

	Electric Clutch	• Inline fuse “blown” (if equipped)
	Not Working	• Inline fuse “blown” (if equipped)
	(Tri-Circuit	• Loose or corroded wires
	(Tri-Circuit	• Open, shorted or grounded wires between output
	Alternator)	• Open, shorted or grounded wires between output
	Alternator)	connector and electric clutch.
		connector and electric clutch.
		• Defective diode (open or shorted – red output lead side)
		• Defective electric clutch switch
		• Open, shorted, or grounded clutch circuit
		• Weak or damaged alternator magnets

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Briggs & Stratton CE8069, 271172, 270962, 276535, 273521 manual Alternator System Diagnosis, Complaint, Possible Causes

Contents

Briggs & ledooStratton Quality Starts With A Master Service TechnicianSingle Cylinder OHV Air-CooledEngines Repair Manuals for other All rights reserved FORWARDCopyright 2009 Briggs & Stratton Corporation This Engine Repair Manual includes the following Engine Models SECTION 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 Before performing adjustments or repairs When testing for spark Explosion and fire could result YOUR KEY TO THE WORLD’S FINEST ENGINES BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEMBRIGGS & STRATTON MODEL NUMBERING SYSTEM ENGINE MAINTENANCE Fuel and Oil RecommendationsFuel must meet these requirements High Altitude Maintenance Chart First 5 Hours Every 8 Hours or DailyEvery 25 Hours or Annually Every 50 Hours or Annually Inspect Brake and Switches Assemble Flywheel Brake Combustion Chamber Air Filter Figure Figure Figure Figure Figure Figure Install Snow HoodRemove Inspection Oil and Oil Filter Spark PlugNOTICE NOTICE Cooling System ENGINE ADJUSTMENTS Remote ControlsRemote Control Wire Travel Horizontal Models 110000, 120000, 2.Move throttle lever to fast position Top No Load Adjustment Vertical Models 97700, Governor AdjustmentsStatic Adjustment 2.Place throttle in FAST position Initial Adjustment All Models Final Adjustment All Models Adjust 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 SYSTEMS CHECK 1 Check IgnitionEngine Stopped Engine Running Testing Fuel Shut Off Solenoid Solenoid Wiring Test2 Check Carburetion Solenoid Plunger Test 3 Check Compression Possible Causes for Poor Compression ELECTRICAL SYSTEMS Equipment Used for TestingDigital Multimeter DC Shunt Possible Causes Alternator System DiagnosisComplaint Alternator Identification 1.0.5 Amp DC Only Figure 2.14 Volt AC Only Figure3.3 Amp DC Only Figure 4.Dual Circuit Figure 8.20 Amp DC Figure 6.5/9 Amp DC Figure7.10/16 Amp DC Figure Testing Alternator Output Flywheel Identification5 Amp DC Only Alternator 3-AmpDC Only Alternator 14-VoltAC Alternator Test Diode Dual Circuit Alternator Test Alternator OutputTest Alternator Output-AC Test Alternator Output-DC Tri-CircuitAlternator Test Diode Charging Circuit Test RED Wire Lighting Circuit Test WHITE WireTest Alternator Output Test Diode Test Regulator-Rectifier 5 & 9 Amp DC Regulated AlternatorTest Alternator Output 10 & 16 Amp DC Regulated Alternator Test Alternator Outputreceptacle Test Regulator - Rectifier 2.Install shunt to negative -battery terminal DC Output Charging Wire Test 20 Amp DC Regulated AlternatorNOTICE Test Alternator Output Figure 5.Rotate selector to DC volts position Model Series 97700, 99700, 110000, ELECTRIC STARTERSSYSTEM 3, SYSTEM Test Interlock Switch Test Starter Motor Test Starter Motor Test Interlock Switch Wiring12 Volt DC Starter Motor Test Solenoid 120-VoltAC Starter MotorModel Series 120000, 150000, 200000, BATTERIES Battery and Cable RecommendationsBattery Installation Charging Battery Testing Battery EQUIPMENT AFFECTING ENGINE OPERATION OIL GARD SYSTEMSHard Starting or Will Not Start Engine Won’t Stop On/Off Switch Light Does Not Flash Engine Starts and Runs With Low Oil SECTION 3 - EXHAUST SYSTEMS MUFFLER SERVICE Spark ArrestersHorizontal Models 110000, 120000, Remove Guard and Muffler Inspect Exhaust System Never reinstall broken or damaged componentsInstall Muffler and Guard Horizontal Models 200000, Shown is a typical muffler application FigureRemove Guard and Muffler 3.Remove muffler support screws A, Figure Never reinstall broken or damaged components Install Muffler and GuardInspect Exhaust System All 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 components Install Muffler and GuardVertical Models 97700, 99700, 110000, Inspect Exhaust System Never reinstall broken or damaged Install Muffler and GuardInspect Exhaust System components Inspect Exhaust System Never reinstall broken or damaged componentsRemove Muffler Install Muffler Never reinstall broken or damaged components Install MufflerShown is a typical muffler application Figure Remove Muffler SECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS Installation Fuel PumpRemoval Inspection Fuel Filter Fuel Tanks and Shut-offValvesHorizontal Models 110000, 120000, 150000, 200000, Removal Installation InstallationVertical Models 97700, 99700, 110000, Vertical Model 2.Inspect fuel tank for •Corrosion •Leaks InstallationInspection CARBURETION Carburetor Identification Remove Carburetor Carburetor Service LMS CarburetorVertical Models 97700, 99700, 110000, Disassemble Carburetor Inspect and Clean Carburetor Components Assemble Carburetor Install Carburetor LMS Carburetor Horizontal Models 110000, 120000, Remove Carburetor Inspect and Clean Carburetor Components Disassemble Carburetor•Passages in the fixed main jet bowl nut Assemble Carburetor edge 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 Inspect and Clean Carburetor Assemble CarburetorPage Install Carburetor bracket.4 Disassemble Carburetor Nikki Carburetor Vertical Models 280000, 310000,Remove Carburetor Inspect and Clean Carburetor 11.Remove the main jet and seal •Choke shaft and choke valve Assemble Carburetor 12.Install new o-ringon fuel transfer tube E Install Carburetor Nikki LP/NG Mixer Vertical Model 310000 Gaseous Fuel SECTION 5 - GOVERNOR SYSTEMS GOVERNOR SYSTEMS Linkage and Spring Orientation Governor Service Governed RPM LimitsHorizontal Models 110000, 120000, 150000, 200000, Disassemble Inspect Governor Assemble Assemble Governor DisassembleInspect Governor 8. Adjust governor system per Section SECTION 6 - CYLINDER HEAD AND VALVES CYLINDER HEADS AND VALVES Remove Cylinder Head Disassemble Cylinder Head Inspection Assemble 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 Remove Cylinder Head Models 200000, 210000, 280000, 310000,Disassemble Cylinder Head Inspection Assemble 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 REWIND STARTERS Remove Blower Housing / Rewind StarterHorizontal Models 110000, 120000, 150000, 200000, Vertical Models 97700, Vertical Models 110000, Disassemble Rewind Starter Service Rewind StarterVertical Model Inspect Rewind Starter Parts Assemble Rewind Starter Vertical Models 110000, 2.Install the oil fill tube and dipstick CVertical Models 97700, Service Starter Clutch Vertical ModelDisassemble Starter Clutch Inspect Clutch Parts ELECTRIC STARTERS Replace Ring GearSystem 3, System Check Starter Drive and Clutch Install Starter Drive and Clutch 12 Volt StartersRemove Starter Drive and Clutch Check Starter Drive and Clutch Assemble Starter Motor Drive - C-Ring Retainer Disassemble Starter Drive - Roll Pin Retainer 120-VoltStarters Assemble Starter Drive - Roll Pin Retainer SECTION 8 - LUBRICATION SYSTEMS EXTENDED OIL FILL AND DIPSTICK BREATHERSInstall Breather Horizontal Models 110000, 120000, 3.Inspect oil drain-backholes C, Figure 3 to make sure they are open. Clean as needed Install BreatherCheck Breather Remove Breather Install Breather 8Current ProductionRemove Breather Check Breather LUBRICATION SYSTEMS Install BreatherOil Dipper Lubrication Oil Slinger Lubrication Oil Pump Service Oil Slinger with Pressure FiltrationPressure Lubrication Vertical Models 120000, 210000, 280000, 310000, Remove Pump Screen Oil Filter and Adapters Remove Install Screen and Gerotor PumpInspect Oil Pump Parts Oil Pressure Switch InstallTest Oil Pressure Switch Oil Gard Systems Lead Wire Colors Lead Wire ColorsTroubleshooting Identification SECTION 9 - CYLINDERS, COVERS AND SUMPS CYLINDER Inspect CylinderReconditioning Bore Resizing Bore MAIN BEARINGS Cleaning CylinderCheck Bearings Check Plain Bearings Replace Bearings Replace DU BearingsMagneto Bearing Tools PTO Bearing Tools Replace Ball Bearing Horizontal Models 120000, Bearing Installation Tools Replace Ball Bearing Horizontal Models 200000,Bearing Removal Tools Tool/Part Replace Ball Bearing All Vertical Models COVERS AND SUMPS Installation Figure Figure FigurePage SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING SYSTEMS, AND GEAR REDUCTIONS CRANKSHAFTS AND CAMSHAFTS Remove Crankshaft and CamshaftInspect Check Crankshaft Install Crankshaft and Camshaft Install Crankcase Cover or Sump Check and Adjust Crankshaft End Play GEAR REDUCTION Disassemble Gear ReductionAssemble Gear Reduction Inspect Gear Reduction Parts Fill Gear Case with Lubricant AUXILIARY PTO InspectionRemove Auxiliary PTO Drive Shaft Assemble Auxiliary PTO Drive Shaft COUNTERBALANCE SYSTEMS Synchro-BalanceSystemDisassemble Remove Counterbalance System Install Assemble Install AVS Balance SystemRemove DisassemblePage SECTION 11 - PISTONS, RINGS AND CONNECTING RODS PISTONS, RINGS, & CONNECTING RODS Remove Piston and Connecting RodDisassemble Inspect Check Ring End Gap Check Connecting RodAssemble Install Piston and Connecting Rod SECTION 12 - ENGINE SPECIFICATIONS MODEL 110000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS MODEL 120000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing MODEL 150000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS MODEL 200000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing MODEL 210000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing MODELS 97700 & 99700 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS MODEL 110000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS MODEL 120000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS MODEL 210000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS MODEL 280000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing MODEL 310000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing MODEL 330000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing