Briggs & Stratton CE8070 Troubleshooting Manual

BRIGGS & STRATTON CORPORATION

Milwaukee, WI 53201

Part No. 190275-5/03 Printed in U.S.A.

Look for these other repair manuals from the Briggs & Stratton Power Products line:

B3277GS Pressure Washer Familiarization

& Troubleshooting Guide

86262 Generator Familiarization &

Troubleshooting Guide

275110 Outboard Motor Repair Manual

Quality Starts With A

Master Service Technician

Visit us at: www.briggsandstratton.com www.generac-portables.com www.briggspowerproducts.com

Familiarization & Troubleshooting Guide

HAND-HELD GENERATOR

For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

FOREWORD

This guide has been written and published by Briggs & Stratton Corporation to aid our dealers’ mechanics and company service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in the recommended servicing procedures for these products, which includes the use of mechanics’ hand tools and any special tools that might be required.

Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems. The troubleshooting, testing,service and repair procedures described in this guide are effective methods of performing such operations.

We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a service might be performed, nor of any possible hazards and/or results of each procedure or method.We have not undertaken any such wide evaluation.Therefore, anyone who uses a procedure or method not described by the manufacturer must first satisfy himself that neither his safety,nor the safety of the product, will be endangered by the service or operating procedure selected.

All information, illustrations,and specifications contained in this guide are based on the latest production information available at the time of publication. However, Briggs & Stratton Corporation reserves the right to change, alter, or otherwise improve the product at any time without prior notice.

Some components or assemblies of the product described in this guide may not be considered repairable. Disassembly,repair and reassembly of such components may not be included in this guide.

No part of this material may be reproduced or transmitted, in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without prior permission in writing from Briggs & Stratton Corporation.

Hand-Held Series Generator

Familiarization & Troubleshooting Guide

Electronic Version #190275 03/03

Please click the “Bookmarks” tab at left to enable the

search and navigational features of this document.

FORWARD

This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and company service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufactured by Briggs & Stratton Power Products Group®. It is also assumed that they have been trained in the recommended servicing procedures for these products, which includes the use of mechanics hand tools and any special tools that might be required.

Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems. The troubleshooting, testing, service and repair procedures described in this guide are effective methods of performing such operations.

We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a service might be performed, nor of any possible hazards and/or results of each procedure or method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by the manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be endangered by the service or operating procedure selected.

All information, illustrations, and specifications contained in this guide are based on the latest production information available at the time of publication. However, Briggs & Stratton Corporation reserves the right to change, alter, or otherwise improve the product at any time without prior notice.

Some components or assemblies of the product described in this guide may not be considered repairable. Disassembly, repair and reassembly of such components may not be included in this guide.

Service and repair instructions for the engines used to power these products are not covered in this guide. Engine service and repair instructions are furnished by the engine manufacturer.

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

TABLE OF CONTENTS

Tabe of Contents

INTRODUCTION

DISASSEMBLY

ASSEMBLY

APPENDIX

TROUBLESHOOTING

In The Interest of Safety 4

Safety Alert Symbols 4

Safety Practices 5

Generator Description 8

Generator Components 9

Serial Number Locations 10

Generator Specifications 10

Wiring Diagram 11

Output Power (AC) 11

Output Power (DC) 11

Fuel System Components 12

Fuel Group 12

General Service Information 12

Work Area 12

Hand Tools 12

Special Tools 12

Under-Voltage (DC) 22

Check (DC) Circuit Breaker 23

Check Bridge Diode 23

Check 12VDC Coil 23

Over-Voltage (AC) 24

Check Capacitor 24

Under-Voltage (AC) 26

Check Receptacle Wiring 27

Check (AC) Circuit Breaker 27

Check Stator Power Winding 28

Check Excitation Winding 28

Check Rotor Winding 29

Engine Switch 29

Pilot Lamp 30

Mounting The Rotor & Stator 33

Installing The Muffler Heat Shield 34

Connecting The Wiring Harness 35

Mount The Rear Case Half 36

Mount The Fuel Tank 37

Mount The Front Case Half 37

Resistance Values 43

Torque Specifications 43

Fasteners and Locations 44

General Disassembly Considerations 15

Case Separation 15

Access To Generator Components 17

Rotor / Stator Removal 18

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

Table of Contents

Section 1 • Introduction

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

INTRODUCTION

Introduction • Section 1

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

In the Interest of Safety

This manual outlines the construction, function and servicing procedures of the Briggs & Stratton Power Products® “Hand-Held” generator series. It is structured for use by trained technicians that are working in a properly equipped shop. Familiarity with the proper method of using tools, measuring equipment and workshop procedures are essential to performing successful maintenance and repair on this equipment.

Ensure that all specified tools and/or equipment are available before attempting to service this equipment.

For a detailed discussion of the fundamental principles involved with the physics of electrical power generation, refer to the "Familiarization and Troubleshooting Guide (Publication #86262 Revision 3 or later)". This manual is available through your Briggs & Stratton Central Distributor.

Safety Alert Symbols

NOTE: This notation is used to

inform you of a method, reference or procedure that could assist with specific operations or decisions.

HAZARD SYMBOLS AND MEANINGS

Toxic Fumes

Electrocution

Hot Surface

Chemical Burns

Explosive Pressure

Kick Back

Entanglement

Disconnect Spark Plug

Fire

Read

Goggles

Explosion

• Operate generator ONLY outdoors.

• Keep at least 2 feet of clearance on all sides of generator for adequate ventilation.

• Do not operate generator inside any building or enclosure, including the generator compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide will cause nausea, fainting or death.

The safety alert symbol ( ) is used to identify safety information about

hazards that can result in personal injury. A signal word (DANGER, WARNING, CAUTION) is used with the alert symbol to indicate the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.

DANGER: Indicates a hazard which, if not avoided will result

in death or serious injury.

WARNING: Indicates a hazard which, if not avoided could result in death or serious injury.

CAUTION: Indicates a hazard which, if not avoided might result in death or serious injury.

CAUTION: When used without the

alert symbol, indicates a situation that could result in damage to equipment.

DANGER

• When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility.

• Use a ground circuit fault interrupter (GFCI) in any damp or highly conductive area, such as metal decking or steel work.

• Do not touch bare wires or receptacles.

• Do not use generator with electrical cords which are worn, frayed, bare or otherwise damaged.

• Do not operate generator in the rain.

• Do not handle generator or electrical cords while standing in water, while barefoot, or while hands or feet are wet.

• Do not allow unqualified persons or children to operate or service generator.

Generator produces powerful voltage.

Failure to isolate generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy.

DANGER

• National electric code requires generator to be properly grounded to an approved earth ground. Call an electrician for local grounding requirements.

Failure to properly ground generator can result in electrocution, especially if the generator is equipped with a wheel kit.

DANGER

Introduction • Section 1

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

Safety Practices

• Generator exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Operate and service this equipment only in the open air where adequate ventilation is available.

• These generators were designed and manufactured for recreational applications. Do not attempt to modify the unit or use it for any application it was not designed for. If you have any questions about your generator's application, ask your dealer or consult the factory.

• The manufacturer could not possibly anticipate every circumstance that might involve a hazard. For that reason, warnings in manuals and warnings on tags or decals affixed to the units are not all-inclusive. If you intend to handle, operate or service a unit with a procedure or method not specifically recommended by the manufacturer, make sure that such a procedure or method will not render the equipment unsafe or pose a threat to you and others.

• Read these procedures carefully and become familiar with your generator set. Know its applications, its limitations and any hazards involved.

• Do not allow any open flame, spark, heat, or lit cigarette around battery during, and for several minutes after charging.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas during recharging.

Hydrogen gas stays around battery for a long time after battery has been charged.

Slightest spark will ignite hydrogen and cause explosion.

You can be blinded or severely injured.

Battery electrolyte fluid contains acid and is extremely caustic.

Contact with battery fluid will cause severe chemical burns.

DANGER

• Do not touch hot surfaces.

• Allow equipment to cool before touching.

Running engines produce heat. Temperature of muffler and nearby areas can reach or exceed 150°F (65°C).

Severe burns can occur on contact.

DANGER

• This generator does not meet U.S. Coast Guard Regulation 33CFR-183 and should not be used on marine applications.

• Failure to use the appropriate U.S. Coast Guard approved generator could result in bodily injury and/or property damage.

WARNING

WHEN ADDING FUEL

• Turn generator OFF and let it cool at least 2 minutes before removing gas cap. Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• Do not overfill tank. Allow space for fuel expansion.

• Keep all fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.

• Do not light a cigarette or smoke.

WHEN OPERATING EQUIPMENT

• Do not tip engine or equipment at angle which causes fuel to spill.

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

• Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF.

• Disconnect spark plug wire.

• Do Not operate generator in a moving vehicle or watercraft, because motion can cause fuel to spill.

WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK

• Store away from furnaces, stoves, water heaters, clothes dryer or other appliances that have pilot light or other ignition source because they can ignite fuel vapors.

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

• Hand-held generators produce a very powerful voltage that can cause an extremely dangerous electrical shock. Avoid contact with bare wires, terminals, etc. Never permit an untrained person to service or assist with the procedures discussed in this guide.

• Never handle any kind of electrical cord or device while standing in water, while barefoot, or while hands or feet are wet.

• Do not use worn, bare, frayed or otherwise damaged electrical cord sets with any generator set. Using a defective cord may result in an electrical shock or damage to the test equipment and/or the unit.

• Gasoline is highly flammable and its vapors are EXPLOSIVE. Do not permit smoking, open flames, sparks or heat in the vicinity while handling gasoline. Avoid spilling gasoline on a hot engine. Comply with all laws regulating storage and handling of gasoline.

• Do not overfill the fuel tank. Always allow room for fuel

expansion. If the tanks are over-filled, fuel can overflow on `to a hot engine and cause FIRE or EXPLOSION.

• These units require an adequate flow of cooling air for their

continued proper operation. Never operate or service any unit while inside any enclosure where the free flow of cooling air into and out of the unit might be obstructed. Without sufficient cooling airflow, the units quickly overheat, damaging the generator and/or nearby property.

• Never start or stop a unit with electrical loads connected

to receptacles and with the connected loads turned ON. Start the engine and let it stabilize before connecting any electrical loads. Turn OFF and disconnect all electrical loads before shutting down any generator.

• This entire book is filled with important safety information

- please read it carefully.

Introduction • Section 1

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

Section 1 • Introduction

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

Item Nomenclature

1. Vibration Mount

2. Bearing Carrier

3. Cooling Fan

4. Rotor Bearing

5. Rotor Bolt (M6-160)

6. Rotor Assembly

7. Stator Bolt (M6-90)

8. Stator Assembly

9. Fuel Tank

10. Fuel Cap

Item Nomenclature

11. Fuel Inlet Filter

12. Spark Plug

13. Generator Case Half

14. Fuel Filter

15. Fuel Hose

16. Fuel Valve

17. Air Cleaner

18. Carburetor

19. Engine

20. Engine Base

GENERATOR DESCRIPTION

Introduction • Section 1

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

Figure 1 — Internal Components

12 13

GENERATOR COMPONENTS

Section 1 • Introduction

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

Figure 2 — External Components

Control Panel

Oil Service Cover

Grounding Lug

Muffler

Spark Plug Access

Recoil Starter

Engine Switch

Air Cleaner

Data Plate

Cooling Fan

Choke Lever

Fuel Shut-Off

Fuel Cap

Serial Number Locations Generator Specifications

Engine:

Name: GM82 or Vanguard

Type: Air Cooled, Four

Cycle Gasoline Engine

Displacement: 80 cubic centimeters

Max. Power: 1.8KW @ 4000RPM

Rated (AC) Power: 1.3KW @ 3000RPM

Oil Capacity: 0.4 Liter

Starting System: Recoil Starter

Oil Alert System: Yes

Generator: N. American Europe

(AC) Frequency: 60Hz

Phase: Single Single

(AC) Rated Voltage: 120 VAC 230VAC

(AC) Rated Current:: 7.5 Amps 3.2 Amps

(AC) Rated Output: 900 VA 750 VA

(AC) Maximum Output: 1000 VA 900 VA

(DC) Output: 12 VDC 12VDC

@ 8.3 Amps @ 8.3 Amps

Voltage Regulator: Condenser Condenser

Rated Power Factor: 1.0 1.0

Rated: Continuous Continuous

Other:

Fuel Capacity: 4.5 Liter / 1.18 Gal 4.5 Liter / 1.18 Gal.

Continuous Operation: 6.4 Hours 6.4 Hours

Noise Level: 63 DBA 63 DBA

@ 7 Meters @ 7 Meters

Dimensions: Length: 465mm 465mm

Width: 343mm 343mm

Height: 371mm 371mm

Dry Weight: 55 lbs. / 25 Kg 55lbs. / 25 Kg

Introduction • Section 1

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

Figure 3 — Engine Serial Number Location

Figure 4 — Generator Serial Number Location

Output Power (AC)

The residual magnetism of the rotor induces an (AC) voltage in the power and excitation windings when the rotor is turned by hand (when recoil starter is pulled). The (AC) voltage of the excitation winding builds in the condenser until it discharges. This "capacitive discharge" then strengthens the magnetic field in the excitation winding. As the rotor windings "cut" this strengthened magnetic field, a higher (AC) voltage is induced in the rotor winding. The diode in the rotor rectifies the induced rotor (AC) to (DC). The intensified magnetic field of the rotor "cuts" across both the power and excitation windings. When the engine starts and spins the rotor, residual magnetism is overcome and this cycle continues to increase the (AC) output voltage of the

power and excitation windings until magnetic saturation and condenser capacity is balanced. This is the calculated "Rated Output" of the generator.

When an external load is plugged into an output receptacle, the increased current flow intensifies the magnetic field of the power winding. As the magnetic field of the rotor "cuts" across the intensified field of the power winding, an additional voltage is induced into the rotor field winding. This increases the output of the power winding to compensate for the voltage drop of the load.

Output Power (DC)

(AC) voltages that are induced into the 12VAC winding are rectified to (DC) by a "full-wave" bridge rectifier.

GENERATOR SYSTEMS

Section 1 • Introduction

Hand-Held Series Generators • Familiarization & Troubleshooting Guide

Figure 5 — Generator Wiring Diagram

+ 35 hidden pages

Briggs & Stratton CE8070 Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual