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Briggs Stratton Lawn Traactor 252700 TO 252799

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Documents

doc1

ENGINE ALTERNATOR REPLACEMENT GUIDE

ThePowerPortal.com

Your One Stop Information Source
Briggs & Stratton has developed a powerful and flexible private web-based portal for its family of products, ThePowerPortal.com. Power Portal Features
Secure, on-demand, 24x7 access to meaningful information and functions for

all of our products.

Role-based security that will dynamically generate an interface and content
which is specific to the various roles of the user.
Interact via the internet for a variety of business transactions. Here is a glimpse of the available features on the brands for which you provide
sales and/or service for.
Brand specific product registration & rebate submission Eclaim - electronic warranty claim filing for engines and end products E-parts - service parts and/or whole goods look-up and ordering Tech press search Re-powering and replacement engine look-up 1,000s of technical and service documents
Use Briggs & Stratton Genuine Parts
Briggs & Stratton engine warranty does not cover engine damage caused by non-original parts. Briggs & Stratton recommends the use of genuine Briggs & Stratton parts for warranty claims.
Identical genuine parts are used in manufacturing Briggs & Stratton engines Genuine parts are engineered and tested for exact fit and performance 1-year limited warranty on original parts (USA-Canada Only)

Table of Contents

Continuity Checks Switches DC Voltage Battery Test Resistance Checks Diode Checks

.... 2.... 2

.... 2..... 3
DC Shunt..... 4 How Does A Shunt Work?.... 4 Ohm's Law Formula..... 5 DC Shunt Instructions..... 7 NoLoad Starter Current Draw 12 Volt Starter Motors 300mV Starter Current Draw 12 Volt Starter Motors 300mV AC Voltage Output Check v DC Amperage Output Check... 8

..... 10....11

Checking DC Amperage Output.... & 20 Amp Regulated Alternator.... 12 Starter Motor Current Draw 120 Volt Starter Motors A... 13
Electric Starter Kits Quick Reference... 14 Alternator Identification..... 15. Engine/Alternator Replacement Information.... 17 Replacing Briggs & Stratton Engines... 17 Briggs & Stratton Engine Replacing Engine Of Another Manufacturer.. 21 Performance Control Electronic Governor.... 40 AWG Wire Sizes..... 41 Metric Wire Gauges..... 41. Load Carrying Capacities.... 41 Glossary of Terms..... 44.
CONTINUITY CHECKS SWITCHES
1. Insert RED test lead into v meter. 2. Insert BLACK test lead into meter. 3. Rotate selector to
receptacle in receptacle in
PUSH BUTTON SWITCH (ELECTRIC START)

ROTARY KEY SWITCH

position.

IGNITION STOP SWITCH

4. When meter test leads are attached to switch terminals and switch is in ON position, a continuous tone indicates continuity. With switch in OFF position, no tone indicates no continuity (incomplete circuit). An incomplete circuit will be displayed as OL.

TOGGLE SWITCH

Continuity Checks

DC VOLTAGE BATTERY TEST

1. Insert RED test lead into v meter. 2. Insert BLACK test lead into meter. 3. Rotate selector to V

receptacle in

4. Connect RED test lead to + (positive) terminal on battery and BLACK test lead to - (negative) terminal. Battery voltage can be checked as shown.
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

DC Voltage Battery Test

RESISTANCE CHECKS
1. Insert RED test lead into v meter. 2. Insert BLACK test lead into meter. 3. Rotate selector to position.
4. Attach test leads to component being tested. 5. Meter will display amount of ohms resistance in component being tested.
TYPICAL 1 OHM RESISTOR FOR TRI-CIRCUIT ALTERNATOR

Resistance Checks

DIODE CHECKS
In the Diode Test position, the meter will display the forward voltage drop across the diode(s). If the voltage drop is less than 0.7 volt, the meter will beep once, as well as display the voltage drop. A continuous tone indicates continuity (shorted diode). An incomplete circuit (open diode) will be displayed as OL. 1. Insert RED test lead into v meter. 2. Insert BLACK test lead into meter. 3. Rotate selector to

TEST LEAD FROM METER

WIRE FROM STATOR

DIODE CONNECTOR

4. Attach RED test lead to point A and BLACK test lead to point B. (It may be necessary to pierce wire with a pin as shown.) a. If meter beeps once, diode is OK. b. If meter makes a continuous tone, diode is defective (shorted). c. If meter displays OL, proceed to step 5. 5. Reverse test leads. a. If meter beeps once, diode is installed backwards. b. If meter still displays OL, diode is defective (open).
TEST LEAD FROM METER BUMP ON CONNECTOR INDICATES DIODE SIDE

3 Amp DC

B TEST LEAD FROM METER CONNECTOR DIODE
Dual Circuit Charging Unit
WIRE FOR CHARGING CIRCUIT TEST LEAD FROM METER

DIODE A

DIODE WIRE FOR LIGHTING CIRCUIT
Tri-Circuit Charging Circuit
Tri-Circuit Lighting Circuit

RED Test Lead B C C D

BLACK Test Lead A B D A

Beep Yes Yes Yes Yes

NOTE: Metal cased rectifiers must also be tested for grounds, as follows: With BLACK test lead probe contacting rectifier case, touch each terminal, A D, with RED test lead probe. Meter should display OL at each terminal. If meter makes a continuous tone at any terminal, rectifier is defective (grounded).

120 Volt Rectifier

DC SHUNT
Have you ever wanted one tool in your toolbox that would make your life so much easier that it would pay for itself after the first couple of uses? That tool might well be the 19359 DC shunt. The DC shunt is a device that enables the technician to make several electrical tests with only one hook-up to the equipment. By using the DC shunt, we can test for system draw with the key switch off, system draw with the key switch on, starter peak amp and steady amp draw, and alternator charging. All of these tests can be done in about 30 seconds taking all the guess work out of the process. Electricity is one of those mysterious entities that most of us are at best, very leery of or at worst, down right frightened of. But once we have a basic understanding of electrical theory, and acknowledge that electricity has to follow strict physical properties, electrical testing becomes one of the easiest troubleshooting problems we will encounter.

(STARTER MOTOR REMOVED FROM ENGINE) To check the no-load amperage draw of a 12 volt starter motor that is removed from the engine, a fixture as shown in the figure should be used. See the diagram for the parts necessary to make a test set-up. CAUTION: DO NOT clamp motor housing in a vise. Starter motors contain two ceramic magnets which can be broken or cracked if the motor housing is deformed or dented. NOTE: When checking starter current draw, battery voltage must not be below 11.7 volts. 1. Install shunt on - (negative) battery terminal. 2. Insert RED test lead into v receptacle in meter and RED receptacle on shunt. 3. Insert BLACK test lead into COM receptacle in meter and BLACK receptacle on shunt.
TACHOMETER NOTE RPM OF STARTER MOTOR TEST LEAD FROM METER PRESS TO START
12 Volt Starter Current Draw DC Shunt
DRILL TWO HOLES 3/8" DIA. FOR STARTER MOUNTING BRACKET PART NUMBER 392749 DRILL TWO HOLES FOR MOUNTING 2-1/4" BRIGGS & STRATTON 57.2 MM PART NUMBER 19200 TACHOMETER #7 DRILL TAP HOLE FOR 1/4-20 NC SCREWS 3-1/2" 89 MM
EXTRA HOLE FOR MOUNTING STARTER BRACKETS

4" 102 MM

3-1/2" 89 MM

1" 25.4 MM

10" 254 MM
METAL STOCK 1/4" THICK STEEL TEST BRACKET

2" 51 MM

Starter Motor Housing Length TABLE 1
How to Make the Test Mounting Bracket
12 VOLT STARTER MOTOR SPECIFICATIONS MOTOR HOUSING LENGTH 3" (76 mm) 3-5/8" (92 mm) 3-3/4" (95 mm) 4-3/8" (111 mm) 4-1/2" (114 mm) MINIMUM RPM 6500

MAXIMUM AMPERAGE 35

4. Rotate meter selector to
5. Activate the starter switch: a. Note RPM on vibration tachometer. b. Note amperage on meter. 6. Note starter motor housing length and refer to
Table 1 for test specifications for starter motor being tested. 7. If the starter motor does not meet the specifications shown in the chart, refer to the Repair Instruction Manual, Section 7, for service and repair procedure. 8
STARTER CURRENT DRAW 12 VOLT STARTER MOTORS 300mV
(STARTER MOTOR MOUNTED ON ENGINE) To check the amperage draw of a starter motor mounted on the engine, the procedure is similar to checking the starter motor off the engine. The battery cable and key switch harness installed in the equipment may be substituted for the test harness shown. When making this current draw test, it is important to monitor the engine RPM, amperage draw and battery voltage. On all 12 volt starter systems, make sure the test is performed with the correct oil in engine, and belts removed from the PTO shaft. Remove the spark plug(s) and ground the spark plug wire(s) using Ignition Tester(s), Tool part number 19368. Also the engine temperature should be at least 68 to 70 F (20 C). Note: When checking starter current draw, battery voltage must not be below 11.7 volts. 1. Install shunt on - (negative) battery terminal. receptacle in 2. Insert RED test lead into v meter and RED receptacle on shunt. 3. Insert BLACK test lead into COM receptacle in meter and BLACK receptacle on shunt. 4. Rotate meter selector to position. 5. Activate the starter switch: a. Note RPM on vibration tachometer. b. Note amperage on meter. 6. If the amperage draw exceeds 100 amps and the engine RPM is less than 350, it could indicate a starter motor problem. Check the starting system, such as the battery, cables, solenoid and connections. Then proceed to check the starter motor by performing the no-load starter motor test as indicated on page 8 or refer to the Briggs & Stratton Repair Instruction Manual, Section 7.

AC LINE VOLTAGE MUST BE NO LESS THAN 110 VOLTS
PUSH SWITCH TO ACTIVATE STARTER
TACHOMETER READ RPM OF STARTER MOTOR
120 Volt AC Starter Motor Current Draw with Line Current Adapter
120 VOLT STARTER MOTOR SPECIFICATIONS STARTER MOTOR IDENTIFICATION American Bosch SME110C3 SME110C6 SME110C8 American Bosch 0602628M030SM Mitsubishi J282188 Briggs & Stratton 3-1/2 (75.45 mm) Motor Housing MAXIMUM AMPERAGE 3.5 MINIMUM RPM 7400

3.0 3.5 2.7

8. If starter motor amperage is within specification, check RPM using vibration tachometer, Tool part number 19200. 9. RPM should be close to specifications listed in Table 4. 13
10.If the starter motor does not meet the given specifications, refer to the Repair Instructions Manual, Section 7.
Electric Starter Kits Quick Reference
Engine Model 190400-196499 190700-195799 252700-252799 253700-253799 194700-198799 195400-195799 19E400-19E499 19F400-19F499 19G400-19G499 19K400-19K499 280700-289799 28A700-28W799 Single Cylinder Intek Engines 120100-15D699786 20A100-21P792157 310700-310799 311700-311799 312700-312799 400400-422499 400700-422799 42A700-42E799 406700-461799 V-Twin Vanguard Engines 303400-303499 354400-354499 350700-350799 380400-381499 380700-381799 303700-303799 304400-304499 350400-350499 351400-351499 351700-351799 381400-381499 381700-381799 V-Twin Intek Engines 405700-405799 406700-406799 407700-407799 445700-445799
RETAINING RING CLUTCH DRIVE RETAINER SPRING WASHER RETURN SPRING STARTER DRIVE ASSEMBLY
Starter Assembly# (Plastic Ring Gear) (Alum. Ring Gear) (Steel Ring Gear) (Plastic Ring Gear/Starter Housing is Over 4" in Length) (Alum. Ring Gear/Starter Housing is Over 4" in Length) (Steel Ring Gear/Starter Housing is Over 4" in Length)
Starter Gear Only# 693713 (Plastic Ring Gear) (Alum. Ring Gear) (Steel Ring Gear)
Drive Assy. # (Bendix) 693699 (C Ring Type) (Roll Pin Type) (Steel Ring Gear)

Single Cylinder Engines

120 volt (60Hz Starter Assembly) 230 volt (50Hz Starter Assembly) 120 volt (60HZ Starter Assembly) 230 volt (50Hz Starter Assembly) (Plastic Ring Gear) (Alum. Ring Gear) (Steel Ring Gear) (3 5/8" Housing) (4 3/8" Housing) (Plastic Ring Gear) (Alum. Ring Gear) (Steel Ring Gear) (Steel Ring Gear) (C Ring Type) (Roll Pin Type) (Steel Pinion Gear) 696541 (C Ring Type)

498148

Opposed Twin Cylinder Engines

(Steel Pinion Gear)

695708 N/A (Steel Pinion Gear)

696541 496881

(C Ring Type) (Steel Pinion Gear)

691564

695708

696541

(C Ring Type)

499521

DUST COVER ROLL PIN-SLOT UP WASHER BEVELED EDGE UP STARTER CLUTCH RETAINING RING UPPER RETAINER SPRING LOWER RETAINER PINION GEAR CLUTCH STARTER MOTOR

PINION GEAR HELIX

C-Ring Type

Roll Pin Type

CONNECTOR YELLOW WIRE TWO YELLOW LEADS

5 or 9 Amp Regulated

493219 Regulator/Rectifier Used With Charge Indicator Circuit
5 or 9 amp DC regulated for charging battery. Alternator output (5 or 9 amp) is determined by flywheel alternator magnet size. Uses same stator as Tri-Circuit system. One BLACK lead from stator. Green connector. 16
Uses same stator as 10 and 16 amp system. DC output the same as 10 or 16 amp system. Charge indicator light and wiring supplied by equipment manufacturer. RED DC output wire to white connector. Blue charge indicator wire to white connector.
ENGINE/ALTERNATOR REPLACEMENT INFORMATION
With the exception of the AC Only alternator, all of the alternator systems referred to in this book have a battery as part of the electrical system. There are specialized applications that use an alternator without a battery. An example would be certain generators or welders that use alternator output to excite an electrical field. For the equipment to function, the alternator output must be very evenly matched to the equipment requirements. When replacing an engine in these applications, the alternator must be the same as the original.
regulated system. We can integrate the two systems by making an adapter harness from readily available parts. Generally an unregulated DC system (DC Only, Dual Circuit) should not be used to replace a regulated system because alternator output may not be sufficient for equipment requirements. However, because the equipment requirements are usually much less on an unregulated DC system, a regulated system may be used as a replacement. The regulator/rectifier prevents the battery from being over charged. NOTE: The AC Only, DC Only, Dual Circuit, TriCircuit as well as the 5 and 10 amp regulated systems use flywheels with small alternator magnets. The 9 and 16 amp regulated systems use flywheels with the large alternator magnets. See figure below for magnet sizes.
Replacing Briggs & Stratton Engines
When replacing an older Briggs & Stratton engine on a piece of equipment with a newer Briggs & Stratton engine, sometimes the newer engine has an alternator system different from the alternator system on the original engine. This means that the output connector on the replacement engine is not compatible with the original wiring harness on the piece of equipment. For example, the original engine may have been equipped with a Dual Circuit system and the replacement engine is equipped with a

*Small Magnet *Large Magnet
7/8" x 11/16" (22mm x 18mm) 1-1/16" x 15/16" (27mm x 24mm)

ALTERNATOR MAGNETS

*V Twin Alternator Magnet Size:Small 7/8" x 21/32" (22 mm x 17 mm) Large 7/8" x 29/32" (22 mm x 23 mm)
The following are alternator replacement combinations which require an adapter harness. All of the necessary components are shown.
1. Original engine equipped with AC Only alternator. Replacement engine equipped with Dual Circuit alternator. Modify 398661 harness supplied with replacement engine by removing RED DC wire. Then, splice 393537 connector into white AC wire and connect to equipment harness.
AC WIRE DUAL CIRCUIT CONNECTOR (FROM ENGINE) AC 393362 HARNESS

EQUIPMENT HARNESS

DC SPLICE RIB RIB 393537 CONNECTOR
2. Original engine equipped with DC Only alternator. Replacement engine equipped with Dual Circuit alternator. Modify 398661 harness supplied with replacement engine by removing white AC wire. Then, splice 393537 connector into RED DC wire and connect to equipment harness.
DUAL CIRCUIT CONNECTOR (FROM ENGINE)

393362 HARNESS

DC WIRE

SPLICE

393537 CONNECTOR
3. Original engine equipped with Dual Circuit alternator. Replacement engine equipped with 5, 9, 10 or 16 amp regulated system. Modify 692306 harness supplied with replacement engine by splicing in 399916 connector assembly. Connect to equipment harness.
399916 CONNECTOR ASSEMBLY OUTPUT CONNECTOR FROM REGULATOR SPLICE

692306 HARNESS

4. Original engine equipped with Tri-Circuit alternator. Replacement engine equipped with 5, 9, 10 or 16 amp regulated system. Modify 692306 harness supplied with replacement engine by splicing into charging circuit wire and lighting circuit wire in equipment harness. NOTE: THE DIODES MUST BE REMOVED FROM THE EQUIPMENT HARNESS.
OUTPUT CONNECTOR FROM REGULATOR

LIGHTING CIRCUIT WIRE

CHARGING CIRCUIT WIRE
Diodes Must Be Removed From Equipment Harness
5. Original engine equipped with Dual Circuit alternator. Replacement engine equipped Tri-Circuit alternator. Discard 691955 diode harness supplied with new engine. Install 794360 regulator/rectifier. Add 692306 harness and modify by splicing in 399916 connector assembly. Connect to equipment harness.
OUTPUT CONNECTOR FROM ALTERNATOR
399916 CONNECTOR ASSEMBLY SPLICE

393422 HARNESS

RIB EQUIPMENT HARNESS
794360 REGULATOR/RECTIFIER
6. Original engine equipped with 5 amp regulated system. Replacement engine equipped with Tri-Circuit alternator. Discard 691955 diode harness supplied with new engine. Transfer 491546 regulator/rectifier from original engine. Connect to equipment harness. The following alternator replacement combinations require no modifications. 7. Original engine equipped with DC Only alternator. Replacement engine equipped with 5, 9, 10 or 16 amp regulated system. Direct Replacement. Connect to equipment harness. 8. Original engine equipped with 5 amp regulated system. Replacement engine equipped with 9, 10 or 16 amp regulated system. Direct Replacement. Connect to equipment harness. 9. Original engine equipped with 9 amp regulated system. Replacement engine equipped with 10 or 16 amp regulated system. Direct Replacement. Connect to equipment harness. 10.Original engine equipped with 10 amp regulated system. Replacement engine equipped with 9 or 16 amp regulated system. Direct Replacement. Connect to equipment harness.

ALTERNATOR

ANTI-AFTERFIRE SOLENOID

STOP SWITCH TERMINAL

KEY SWITCH
AC OUTPUT WIRE DC OUTPUT WIRE
AMMETER HEADLIGHTS HEADLIGHT SWITCH

BATTERY TERMINAL

SOLENOID TAB TERMINAL STARTER TERMINAL

SOLENOID

12 VOLT BATTERY

STARTER MOTOR

Typical Dual Circuit Alternator Wiring Diagram Original 5 Pole Switch Superceded to 6 Pole Switch, Briggs & Stratton Part Number 692318
Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 2+5 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case

Terminal No. 5

Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid)

AMMETER

AMMETER (OPTIONAL) HEADLIGHTS HEADLIGHT SWITCH BATTERY TERMINAL
Typical Dual Circuit Alternator Wiring Diagram 6 Pole Switch Briggs & Stratton Part Number 692318 With ammeter shown in optional position, note that and + symbols are reversed. The + symbol must always be connected to the alternator side. Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 + 6 2+5+6 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Terminal No. Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid) To Alternator (DC Output)

STARTER SOLENOID STATOR

STARTER
DIODE WHITE CONNECTOR RED DC OUTPUT

BLACK AC OUTPUT

LIGHT SWITCH
AMMETER BATTERY START SWITCH 6 1
Typical Dual Circuit System

ALTERNATOR KEY SWITCH

AC OUTPUT WIRE

DC OUTPUT WIRE

SOLENOID TAB TERMINAL BATTERY TERMINAL STARTER TERMINAL
HEADLIGHTS HEADLIGHT SWITCH SOLENOID
Typical 16 Amp Regulated Alternator Wiring Diagram 5 Pole Switch Briggs & Stratton Part Number 692318
AMMETER REGULATOR/ RECTIFIER

AMMETER (OPTIONAL)

SOLENOID TAB TERMINAL

STARTER TERMINAL

HEADLIGHTS HEADLIGHT SWITCH
Typical 16 Amp Regulated Alternator Wiring Diagram 6 Pole Switch Briggs & Stratton Part Number 692318 With ammeter shown in optional position, note that and + symbols are reversed. The + symbol must always be connected to the alternator side. Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 + 6 2+5+6 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Terminal No. Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid) To Alternator (DC Output)

CHARGE INDICATOR LIGHT

BLUE WIRE
REGULATOR/ RECTIFIER RED WIRE DC OUTPUT RAISED RIB

8-WAY CONNECTOR TERMINAL #

SIGNAL ---

CARB MANIFOLD ASSEMBLY

12 VOLT POWER (GND)

TERMINAL # 7 8
12 VOLT POWER (+) ----12 VOLT POWER (GND) 12 VOLT POWER (+) ---
SIGNAL STEPPER MOTOR WIRE E (12 VOLT (+) INPUT STEPPER MOTOR WIRE A STEPPER MOTOR WIRE B IGNITION WIRE PRIMARY STEPPER MOTOR WIRE D STEPPER MOTOR WIRE C

STEPPER MOTOR ASSEMBLY

2-WAY CONNECTOR SIGNAL

TERMINAL #

THERMISTOR (SIGNAL)

THERMISTOR (GND)

GRAY GRAY
CARB SOLENOID BLACK GRAY BLACK BLACK
THERMISTER EFM PULSE SIGNAL BLACK
GROUND (ON CYLINDER SHIELD)
YELLOW YELLOW RED GRAY 16 AMP CIRCUIT OPTION STATOR 5 & 9 AMP CIRCUIT OPTION RED BLACK RED RED 6 PIN CONNECTOR (ENGINE SIDE)

CYLINDER #2 ARMATURE

6 PIN CONNECTOR TERMINAL ENGINE TERMINATION POINT POWER SUPPLY FROM REGULATOR CYLINDER #1 & #2 ARMATURE CARB SOLENOID POWER SUPPLY FROM REGUALTOR OPEN OPEN WIRE COLOR RED BLACK GRAY RED 4 1

CYLINDER #1 ARMATURE

WIRE CONNECTORS

V-TWIN 6 PIN CONNECTOR

ENGINE CONNECTION
AMP PIN HOUSING (FEMALE-CAP)

APPLICATION CONNECTION

AMP SOCKET HOUSING (MALE-PLUG)
RIB IS AT HOLE #1 HOLE #4 "LIGHT SWITCH" COLOR: ORANGE HOLE #1 "ALTERNATOR" COLOR: RED HOLE #5 "OIL SWITCH" COLOR: GREEN HOLE #2 "MAGNETO" COLOR: BLACK HOLE #6 "OPEN" HOLE #3 "FUEL SOLENOID" COLOR: GREY "A" TERMINAL TO OIL LIGHT KEYSWITCH "M" TERMINAL KEYSWITCH "L" TERMINAL TO LIGHT SWITCH
V-TWIN WITH DUAL 2 PIN CONNECTORS
HOLE #1 "3 AMP ALTERNATOR AC" COLOR: RED HOLE #2 "3 AMP ALTERNATOR AC" COLOR: RED

TO LIGHT SWITCH

KEYSWITCH "A" TERMINAL
HOLE #1 "MAGNETO" COLOR: BLACK
KEYSWITCH "M" TERMINAL KEYSWITCH "L" TERMINAL
HOLE #2 "FUEL SOLENOID" COLOR: GREY
V-TWIN WITH 2 PIN CONNECTOR AND 1 PIN CONNECTOR
"ALTERNATOR" COLOR: RED
HOLE #1 "MAGNETO" COLOR: BLACK HOLE #2 "FUEL SOLENOID" COLOR: GREY

typical 8-pin connector

VOLTAGE REGULATOR (RED)

Left Side View

STARTER SOLENOID TAB (YELLOW) WIRE END

GROUND (BROWN)

IGNITION KILL (BLACK)

OIL PRESSURE (GREEN)

OPEN SLOT

OPEN SLOT TERMINAL END

WIRE END

TERMINAL END

FUEL CUT-OFF (GRAY) OIL PRESSURE (GREEN) CUSTOMER CONNECTION STARTER SOLENOID BATTERY + (ORANGE)

Top View

VIEW FROM TERMINAL END
TO FIT INDAK KEY SWITCH FOR.032 TAB THICKNESS

Right Side View

Bottom View
PERFORMANCE CONTROL ELECTRONIC GOVERNOR
Some Vanguard V-Twin engines are equipped with the Performance Control electronic governor control system for generator or welder applications. The electronic governor provides more responsive governing than a mechanical governor system. Engines equipped with the Performance Control electronic governor control system have no mechanical governor components. The Performance Control electronic governor control system cannot be retrofitted to mechanical governor engines. The Performance Control electronic governor control system consists of an electronic control module, wiring and stop switch harness and a throttle actuator. The control module is equipped with an idle down circuit for applications requiring that feature. By cutting the yellow wire loop, the control module may be converted to 50 cycle 3000 RPM generator applications. The engine must be turned off when cutting Yellow Cycle loop, then start the engine for the system to reset the engines RPM for 50Hz cycle.
CARBURETOR SOLENOID IDLE DOWN DEVICE
WHITE 50 CYCLE 3000 RPM LOOP STOP SWITCH TERMINAL

MODULE GREEN RED

ACTUATOR

YELLOW

AC OUTPUT WIRES DC OUTPUT WIRE
STOP SWITCH HARNESS DIODE DIODE
REGULATOR/ RECTIFIER BATTERY TERMINAL

IGNITION COILS

Performance Control Electronic Governor Wiring Diagram
AWG Wire Sizes (see table on the next page)
AWG: In the American Wire Gauge (AWG), diameters can be calculated by applying the formula D(AWG)=.00592((36-AWG)/39) inch. For the 00, 000, 0000 etc. gauges you use -1, -2, -3, which makes more sense mathematically than double nought. This means that in American wire gage every 6 gauge decrease gives a doubling of the wire diameter, and every 3 gauge decrease doubles the wire cross sectional area. Similar to dB in signal and power levels. An approximate form of this formula contributed by Mario Rodriguez is D =.460 * (57/64)(awg +3) or D =.460 * (0.890625)(awg +3).
Metric Wire Gauges (see table on the next page)
Metric Gauge: In the Metric Gauge scale, the gauge is 10 times the diameter in millimeters, so a 50 gauge metric wire would be 5 mm in diameter. Note that in AWG the diameter goes up as the gauge goes down, but for metric gauges it is the opposite. Probably because of this confusion, most of the time metric sized wire is specified in millimeters rather than metric gauges.

Load Carrying Capacities (see table on the next page)
The following chart is a guideline of ampacity or copper wire current carrying capacity following the Handbook of Electronic Tables and Formulas for American Wire Gauge. As you might guess, the rated ampacities are just a rule of thumb. In careful engineering the voltage drop, insulation temperature limit, thickness, thermal conductivity, and air convection and temperature should all be taken into account. The Maximum Amps for Power Transmission uses the 700 circular mils per amp rule, which is very conservative. The Maximum Amps for Chassis Wiring is also a conservative rating, but is meant for wiring in air, and not in a bundle. For short lengths of wire, such as is used in battery packs you should trade off the resistance and load with size, weight, and flexibility. NOTE: For installations that need to conform to the National Electrical Code, you must use their guidelines. Contact your local electrician to find out what is legal!
AWG gauge Metric 2.Metric 1.Metric 1.Metric 1.Metric 1.Metric 1.Metric 40
Conductor Diameter Inches 0.46 0.4096 0.3648 0.3249 0.2893 0.2576 0.2294 0.2043 0.1819 0.162 0.1443 0.1285 0.1144 0.1019 0.0907 0.0808 0.072 0.0641 0.0571 0.0508 0.0453 0.0403 0.0359 0.032 0.0285 0.0254 0.0226 0.0201 0.0179 0.0159 0.0142 0.0126 0.0113 0.01 0.0089 0.008 0.00787 0.0071 0.00709 0.0063 0.0063 0.0056.00551 0.005.00492 0.0045.00441 0.004.00394 0.0035 0.0031
Conductor Diameter mm 11.684 10.40384 9.26592 8.25246 7.34822 6.54304 5.82676 5.18922 4.62026 4.1148 3.66522 3.2639 2.90576 2.58826 2.30378 2.05232 1.8288 1.62814 1.45034 1.29032 1.15062 1.02362 0.91186 0.8128 0.7239 0.64516 0.57404 0.51054 0.45466 0.40386 0.36068 0.32004 0.28702 0.254 0.22606 0.2032 0.200 0.18034 0.180 0.16002 0.16002 0.14224.140 0.127 0.125 0.1143 0.112 0.1016 0.1000 0.0889 0.07874
Ohms per 1000 ft. 0.049 0.0618 0.0779 0.0983 0.1239 0.1563 0.197 0.2485 0.3133 0.3951 0.4982 0.6282 0.7921 0.9989 1.26 1.588 2.003 2.525 3.184 4.016 5.064 6.385 8.051 10.15 12.8 16.14 20.36 25.67 32.37 40.81 51.47 64.9 81.83 103.2 130.1 164.1 169.39 206.9 207.5 260.9 260.339 414.8 428.2 523.1 533.8 659.6 670.2 831.8 1049
Ohms per km 0.16072 0.202704 0.255512 0.322424 0.406392 0.512664 0.64616 0.81508 1.027624 1.295928 1.634096 2.060496 2.598088 3.276392 4.1328 5.20864 6.56984 8.282 10.44352 13.17248 16.60992 20.9428 26.40728 33.292 41.984 52.9392 66.7808 84.1976 106.1736 133.8568 168.8216 212.872 268.4024 338.496 426.728 538.248 555.61 678.632 680.55 855.752 855.752 1079.2728 3440
Maximum amps for chassis wiring 4.7 3.5 2.7 2.2 1.7 1.4 1.2 0.86 0.7 0.53 0.51 0.43 0.43 0.33 0.33 0.27 0.26 0.21 0.20 0.17 0.163 0.13 0.126 0.11 0.09

lamination stack: An electrical component that consists of thin iron layers used to focus and control the lines of magnetic flux. lead-acid battery: A battery that stores electrical energy using lead cell plates and sulfuric acid (H2SO4). limited angle torque (LAT) motor: A direct current (DC) motor used to control governor system components in an electronic governor system. load: A device that uses electricity, such as the starter motor, lights, or other application accessories.
magnet: A material that attracts iron and produces a magnetic field. magnetic field: An area of magnetic force created and defined by lines of magnetic flux surrounding a material in three dimensions. magnetic flux: The invisible lines of force in a magnetic field. magnetism: An atomic level force derived from the atomic structure and motion of certain orbiting electrons in a substance. magneto: An alternator with permanent magnets used to generate current for ignition in an internal combustion engine. Magnetron ignition system: An ignition system that uses electronic components in place of breaker points and a condenser. manual switch: A switch operated by a person. mechanical switch: A switch operated by the movement of an object. milliamp: An expression meaning 1/1000th of an amp. millivolt: An expression meaning 1/1000th of a volt. neutrons: The neutral parts of an atom which have no electrical charge.
rated speed: Revolutions per minute at which the set is designed to operate.
rated voltage: The rated voltage of an engine generator set is the voltage at which it is designed to operate. rear bearing carrier: The casting which houses the rotor bearing which supports the rotor shaft. rectifier: An electrical component that converts AC to DC by allowing the current to flow in only one direction. regulator/rectifier: An electrical component that contains one or more diodes and a zener diode. relay: An electrically operated switch usually used in control circuits and whose contacts are considered low amperage, compared to a contactor. reserve capacity: The amount of time a battery can produce 25A at 80 F (26 degrees C). resistance (R): The opposition to the flow of electrons. resistive load: An applied load that reduces the possibility of the alternator system delivering full amperage through the circuit. rotor: The rotating element of a generator. secondary winding: A coil in which high voltage is induced for use at the spark plug. self-inductance: A magnetic field created around a conductor whenever current moves through the conductor. series circuit: A circuit having two or more components connected so that there is only one path for current flow. series/parallel circuit: A circuit that contains a combination of components connected in series and parallel. short circuit: An undesirable complete circuit path that bypasses the intended path and has very little resistance. silicon controlled rectifier (SCR): A semiconductor that is normally an open circuit until voltage is applied, which switches it to the conducting state in one direction. single phase: An AC load, or source of power normally having only two input terminals if a load or two output terminals if a source. solenoid: A device that converts electrical energy into linear motion. spark gap: The distance from the center electrode to the ground electrode on the spark plug. 47

spark plug: A component that isolates the electricity induced in the secondary windings and directs a high voltage charge to the spark gap at the tip of the spark plug. spark tester: A test tool used to test the condition of the ignition system on a small engine. starter motor: An electric motor that drives the engine flywheel when starting. starter solenoid: An electrical switch, with internal contacts opened or closed, using a magnetic field produced by a coil. stator: An electrical component that has a continuous copper wire (stator winding) wound on separate stubs exposing the wire to a magnetic field. switch: Any component that is designed to start, stop, or redirect the flow of current in an electrical circuit.
temporary (soft) magnet: A magnet that can only become magnetic in the presence of an external magnetic field. trigger: A magnetic pick-up located near the crankshaft pulley that senses and counts crankshaft rotation. troubleshooting: The systematic elimination of the various parts of a system or process to locate a malfunctioning part. vibration mount: A rubber device located between the engine or generator and the cradle to minimize vibration. volt (V): The unit of measure for electrical pressure difference between two points in a conductor or device. voltage: The amount of electrical pressure in a circuit. voltage regulator: A component which automatically maintains proper generator voltage by controlling the amount of DC exitation to the rotor. voltage regulation system: A system that controls the amount of voltage required to charge the battery with a regulator/rectifier. voltage source: A battery or some other voltage producing device.
watt: Unit of electrical power. In DC equals volts times amperes. In AC equals effective volts times effective amps times power factor times a consistent dependent on the number of phases. 1 kilowatt 1,000 watts. winding: All the coils of a generator. Stator winding consists of a number stator coils and their interconnections. Rotor windings consist of all windings and connections on the rotor poles. zener diode: A semiconductor that senses voltage to measure the state of battery charge at the battery terminals.
Briggs & Stratton Alternator Chart
You can order this chart from your source of supply or on ThePowerPortal.com under Customer Education.
MS-2288FL.qxp 10/23/2008 10:24 Page 1
BRIGGS & STRATTON ALTERNATOR CHART

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