Briggs & Stratton 30473 manual

POWERSMART SERIES™ INVERTER GENERATOR SERVICE AND REPAIR MANUAL MODEL 030473 279957GS Rev. - This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators) Not for Reproduction[...]

2 BRIGGSandSTRATTON.COM Briggs & Stratton Power Products Group, LLC P.O. Box 702 Milwaukee, WI 53201-0702 Copyright © 2010. All rights reserved. No part of this material may be reproduced or transmitted in any form without the express written permission of Briggs & Stratton Power Products Group, LLC. Not for Reproduction[...]

3 Table of Contents Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4 Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

4 BRIGGSandSTRATTON.COM Important Safety Instructions 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 Certain components in this product and related accessories contain chemicals known to the State of California to cause cancer, birt[...]

5 WARNING Generator voltage could cause electrical shock or burn resulting in death or serious injury. Use approved transfer equipment to prevent backfeed bt isolating generator from electric utility workers. • When using generator for backup power, notify utility company. • Use a ground fault circuit interrupter (GFCI) in any damp or highly co[...]

6 BRIGGSandSTRATTON.COM CAUTION Excessively high operating speeds could result in minor injury and/or equipment damage. Excessively low speeds impose a heavy load on generator. • DO NOT tamper with governed speed. Generator supplies correct rated frequency and voltage when running at governed speed. • DO NOT modify generator in any way. NOTICE?[...]

7 WARNING Exhaust heat/gases could ignite combustibles or structures resulting in death, serious injury and/or property damage. • Keep at least 5 feet (152 cm) of clearance on all sides of generator including overhead. Generator Location For proper clearance and air movement, place generator outdoors in an area that will not accumulate deadly exh[...]

8 BRIGGSandSTRATTON.COM Fuel Tank Cap Vent Lever The fuel tank cap is provided with a vent lever ( A , Figure 2) to seal the fuel tank. The vent lever must be in the “ON” position for the engine to run. When the engine is not in use, leave the vent lever in the “OFF” position to reduce the possibility of fuel leakage. Allow the engine to co[...]

9 Generator Components A - Fuel Tank Cap Vent Lever — Turn the vent lever to the “ON” position when operating the generator. Turn to the “OFF” position when not in use. B - Fuel Tank — Capacity of 1.0 U.S. gallon (3.7L). C - Choke Lever — Used when starting cold engine. D - Side Maintenance Cover — Remove to gain access for air clea[...]

10 BRIGGSandSTRATTON.COM Maintenance Maintenance Schedule Follow the hourly or calendar interval, whichever occurs first. More frequent service is required when operating in adverse conditions noted below. Every 8 Hours or Daily • Clean debris • Check engine oil level First 10 Hours • Change engine oil Every 50 Hours or 3 Months • Service e[...]

11 WARNING Unintentional sparking could cause fire or electric shock resulting in death or serious injury. When Adjusting Or Making Repairs To The Generator • Disconnect the spark plug wire from the spark plug and place the wire where is cannot contact spark plug. When Testing For Engine Spark • Use approved spark plug tester • DO NOT check f[...]

12 BRIGGSandSTRATTON.COM Changing Engine Oil If the generator is used under extremely dirty or dusty conditions, or in extremely hot weather, change the oil more often. CAUTION Avoid prolonged or repeated skin contact with used motor oil. • Used motor oil has been shown to cause skin cancer in certain laboratory animals. • Thoroughly wash expos[...]

13 Service Spark Plug 1. Loosen the four handle screws and remove the handle (Figure 8). Figure 8 2. Remove the top maintenance cover. 3. Clean area around spark plug and remove spark plug boot (Figure 9). Figure 9 4. Remove spark plug and inspect for pitting, corosion, cracks, or other signs of damage. 5. Check electrode gap with wire feeler gauge[...]

14 BRIGGSandSTRATTON.COM Inspect Muffler and Spark Arrester Inspect the muffler for cracks, corrosion, or other damage. Remove the spark arrester, if equipped, and inspect for damage or carbon blockage. WARNING Exhaust heat/gases could ignite combustibles or structures resulting in death, serious injury and/or property damage. Contact with muffler [...]

15 Rewind Starter Replacement Disassemble Rewind Starter 1. Remove control panel, inverter, and fuel tank as described in the Troubleshooting section. 2. Locate the rewind starter handle ( A , Figure 13) and remove the screw that is located under the handle. 3. Push the handle assembly through the generator enclosure (Figure 14). Figure 14 4. Pull [...]

16 BRIGGSandSTRATTON.COM Figure 15 Inspect Rewind Starter Parts 1. Inspect the pulley for wear, cracks, rough edges, or burrs in the rope groove and look for wear in the center hole. If wear or damage is found, replace the pulley and spring assembly. 2. Inspect the spring for broken ends, kinks, or burrs. If damage is found, replace the pulley and [...]

17 Troubleshooting Fuel System Fuel Pump The fuel pump ( A , Figure 16) is located on inside of cover. It is operated by vacuum pulses from the engine. The fuel pump is not serviceable. If the pump does not operate after inspection, replace the pump. Inspect pump for: • Ensure vacuum hose is connected properly • Restrictions or leaks in vacuum [...]

18 BRIGGSandSTRATTON.COM Fuel Valve The fuel valve is mounted behind the side maintenance cover. Check the valve for proper operation as follows: 1. Using small, flat-head screwdriver, pry off cover to the fuel valve knob (Figure 19). Figure 19 2. Remove screw under the cover to remove the knob ( B , Figure 20). 3. Check the fuel valve for leaks ( [...]

19 2. Remove control panel from enclosure and, without disconnecting wiring, set control panel aside ( D , Figure 23). 3. Remove inverter from enclosure ( E ) and, without disconnecting wiring, set inverter assembly aside. Figure 23 E D 4. Close vent on fuel cap. Carefully spread ends of generator housing to remove fuel tank (Figure 24) from unit. [...]

20 BRIGGSandSTRATTON.COM 4. Remove breather filter ( B , Figure 29) to expose the air cleaner assembly screw. Loosen and remove screws ( C ) to remove air cleaner assembly. 3. Remove screw from air filter cover (Figure 28). Set cover aside. Figure 28 Figure 29 B C Carburetor Inspect carburetor for: • Blockage • Leaks • Varnish or Gummy Residu[...]

21 5. Remove air cleaner assembly and set aside (Figure 30). Figure 30 7. Remove the hose that is connected to carburetor assembly (Figure 32). 8. While leaving the stepper motor attached, carefully slide carburetor assembly off engine. 9. Remove bowl nut (Figure 33) and the fuel bowl. Check for damage, leaks, and gummy residue. Figure 32 Figure 33[...]

22 BRIGGSandSTRATTON.COM 11. Ensure the inlet needle and spring ( A ) are assembled correctly, with the spring located below the float bosses (Figure 35). 12. Using a carburetor nozzle screwdriver, remove the main jet and emulsion tube (Figure 36). Clean as needed. 13. Using carburetor cleaner, thoroughly clean the following components, then follow[...]

23 Stepper Motor The stepper motor (electric throttle actuator) responds to the inverter module to continuously match engine speed to the power needs of the generator. The stepper motor (Figure 37) is attached to the top of the carburetor assembly. Figure 37 Before removing the motor assembly, first check the resistance of the motor lead wires. 1. [...]

24 BRIGGSandSTRATTON.COM 4. Actuate the throttle lever to check for proper movement (Figure 42). The lever should move freely in both directions. 5. If the linkages stick, spray lubricant on the lever and manually move the lever. This should free the linkages. If not, replace the carburetor. Figure 42 2. Remove two screws that hold the stepper moto[...]

25 Engine Will Not Start The Engine Cranks But Has No Spark If the engine cranks but has no spark, it could be the micro switch ( A , Figure 43). Test the continuity of the microswitch as follows: 1. Remove the control panel. 2. Disconnect the 10-pin connector (Figure 44) that is connected to the ignition module (module with three LED lights). Figu[...]

26 BRIGGSandSTRATTON.COM Low Oil Switch The low oil indicator system is designed to prevent engine damage caused from insufficient engine oil. If the engine oil level drops below a preset level, the yellow LED low oil indicator light (Figure 47) illuminates and an oil switch will stop the engine. Figure 47 If the engine will not start and the low o[...]

27 Ignition Spark Circuit When the engine is running the 27V coil produces a voltage that is present at the ignition module. When the magnet on the flywheel (rotor) passes by the trigger coil, this trigger voltage is sensed by the ignition module. When the ignition module senses this trigger voltage, the module sends the voltage from the 27V coil i[...]

28 BRIGGSandSTRATTON.COM Test Ignition Coil 1. Locate the connector for the ignition coil ( A , Figure 56) and disconnect.. 2. Attach meter test leads to primary side of the ignition coil and measure the resistance ( B , Figure 57). • If resistance is 0.8 - 1.3 Ω the primary coil is good. • If resistance is not to specifications, check wire co[...]

29 Figure 58 3. Attach one test lead to either terminal of ignition coil connector and the other lead to the spark plug cap (Figure 58) to measure the secondary resistance. Trigger Coil and Rotor Clearance 1. Remove the engine shroud. 2. Using the appropriate feeler gauge, measure the clearance between the trigger coil and the rotor ( A , Figure 59[...]

30 BRIGGSandSTRATTON.COM 3. Measure for 120 VAC ouput ( C , Figure 62). 4. Disconnect the main winding connector and measure resistance across the windings ( D , Figure 63). 5. Then measure resistance across sub-windings ( E , Figure 64). • If resistance is 1.35 - 1.75 Ω the windings are good. • If resistance is not to specifications, check wi[...]

31 2. Disassemble panel cover to locate and check the wire connections ( A , Figure 66). 3. Locate battery winding connector ( B , Figure 67) and mesure resistance across the terminals ( C ). Figure 66 A A • If resistance is 0.3 - 0.7 Ω the winding is good. • If resistance is not to specification, check wire connections, or repair/repace wires[...]

32 BRIGGSandSTRATTON.COM Generator Specifications Starting Wattage 2,000 Watts Wattage* 1,600 W atts Load Current at 120 Volts AC 13.3 Amps at 12 Volts DC 5 Amps Rated Frequency 60 Hertz Phase Single Phase Displacement 6.44 cu. in. (105.6 cc) Spark Plug Gap .025 in. (.65 mm) Intake Valve Clearance .003 - .005 in. (.08 - .13 mm) cold Exhaust Valve C[...]

33 Generator Wiring Diagram Not for Reproduction[...]

Not for Reproduction[...]