Briggs & Stratton Powersmart 30473 Installation and operating 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)
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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.
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Table of Contents
Important Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . 4
Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rewind Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
No AC Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
No DC Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 30
Generator Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 31
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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, birth defects, or other
reproductive harm. Wash hands after handling.
WARNING Running engine gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide could result in death,
serious injury, headache, fatigue, dizziness,
vomiting, confusion, seizures, nausea or fainting.
• Operate this product ONLY outdoors.
• Install a battery operated carbon monoxide alarm near
the bedrooms.
• Keep exhaust gas from entering a confined area through
windows, doors, ventilation intakes, or other openings.
SAVE THESE INSTRUCTIONS - This manual contains
important instructions that should be followed during
installation and maintenance of the generator and batteries.
Safety Symbols and Meanings
The safety alert symbol indicates a potential personal
injury hazard. A signal word (DANGER, WARNING, or
CAUTION) is used with the alert symbol to designate a degree
or level of hazard seriousness. A safety symbol may be used
to represent the type of hazard. The signal word NOTICE is
used to address practices not related to personal injury.
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, could
result in minor or moderate injury.
NOTICE addresses practices not related to personal injury.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in
this manual, and the tags and decals affixed to the unit are,
therefore, not all-inclusive. If you use a procedure, work
method or operating technique that the manufacturer does
not specifically recommend, you must satisfy yourself that
it is safe for you and others. You must also make sure that
the procedure, work method or operating technique that you
choose does not render the generator system unsafe.
Kickback
Fire
Flying Objects Hot SurfaceMoving Parts
Read ManualExplosion
Electrical ShockToxic Fumes
Explosive Pressure Chemical Burn
WARNING
• 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 death or serious injury and/or
property damage.
WARNING Starter cord kickback (rapid retraction)
will pull hand and arm toward engine faster than
you can let go which could cause broken bones,
fractures, bruises, or sprains resulting in serious
injury.
• When starting engine, pull cord slowly until resistance is
felt and then pull rapidly to avoid kickback.
• Never start or stop engine with electrical devices plugged
in and turned on.
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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 conductive area, such as metal decking or steel
work.
• DO NOT touch bare wires or bare receptacles.
• DO NOT use generator with electrical cords which are
worn, frayed, bare or otherwise damaged.
• DO NOT operate the generator in the rain or wet weather.
• DO NOT handle generator or electrical cords while
standing in water, while barefoot, or while hands and
feet are wet.
• DO NOT allow unqualified persons or children to operate
or service generator.
WARNING Fuel and its vapors are extremely flammable
and explosive which could cause burns,
fire, or explosion resulting in death, serious
injury, and/or property damage.
When Adding or Draining Fuel
• Turn generator engine OFF and let it cool at least 2
minutes before removing fuel cap. Loosen cap slowly to
relieve pressure in tank.
• Fill or drain tank outdoors.
• DO NOT overfill tank. Allow space for fuel expansion.
• If fuel spills, wait until it evaporates before starting
engine.
• Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources.
• Check fuel lines, tank, cap, and fittings frequently for
cracks or leaks. Replace if necessary.
• DO NOT light a cigarette or smoke.
When Starting Equipment
• Ensure spark plug, muffler, fuel cap, and air cleaner are in
place.
• DO NOT crank engine with spark plug removed.
When Operating Equipment
• DO NOT operate this product inside any building, carport,
porch, mobile equipment, marine applications, or
enclosure.
• DO NOT tip engine or equipment at angle which causes
fuel to spill.
• DO NOT stop engine by moving choke to “CHOKE”
position.
When Transporting, Moving, or Repairing Equipment
• Transport/move/repair with fuel tank EMPTY or with fuel
shutoff valve OFF.
• DO NOT tip engine or equipment at angle which causes
fuel to spill.
• Disconnect spark plug wire.
When Storing Fuel or Equipment with Fuel in Tank
• Store away from furnaces, stoves, water heaters, clothes
dryers, or other appliances that have pilot light or other
ignition source because they could ignite fuel vapors.
WARNING Exhaust heat/gases could ignite combustibles
or structures resulting in death, serious
injury and/or property damage.
Contact with muffler area could cause
burns resulting in serious injury.
• DO NOT touch hot parts and AVOID hot exhaust gases.
• Allow equipment to cool before touching.
• DO NOT install the generator closer than 5 feet (1.5m)
from any combustibles or structures with combustible
walls having a fire resistance rating of less than 1 hour.
• Keep at least minimum distances shown in General
Location Guidelines to insure for proper generator cooling
and maintenance clearances.
• It is a violation of California Public Resource Code,
Section 4442, to use or operate the engine on any forest-
covered, brush-covered, or grass-covered land unless
the exhaust system is equipped with a spark arrester, as
defined in Section 4442, maintained in effective working
order. Other states or federal jurisdictions may have
similar laws.
Contact the original equipment manufacturer, retailer, or
dealer to obtain a spark arrester designed for the exhaust
system installed on this engine.
• Replacement parts must be the same and installed in the
same position as the original parts.
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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 Exceeding generators wattage/amperage
capacity could damage generator and/or electrical devices
connected to it.
• DO NOT exceed the generator’s wattage/amperage
capacity. See Don’t Overload Generator in the Operator’s
Manual.
• Start generator and let engine stabilize before connecting
electrical loads.
• Connect electrical loads in OFF position, then turn ON for
operation.
• Turn electrical loads OFF and disconnect from generator
before stopping generator.
NOTICE Improper treatment of generator could damage it
and shorten its life.
• Use generator only for intended uses.
• If you have questions about intended use, contact your
authorized dealer.
• Operate generator only on level surfaces.
• DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.
• Remain alert at all times while working on this equipment.
Never work on the equipment when you are physically
or mentally fatigued.
• DO NOT start engine with air cleaner or air cleaner
cover removed.
• DO NOT insert any objects through cooling slots.
• DO NOT use the generator or any of its parts as a step.
Stepping on the unit could cause stress and break parts.
This may result in dangerous operating conditions from
leaking exhaust gases, fuel leakage, oil leakage, etc.
• If connected devices overheat, turn them off and
disconnect them from generator.
• Shut off generator if
- electrical output is lost;
- equipment sparks, smokes, or emits flames;
- unit vibrates excessively.
WARNING Unintentional sparking could cause fire or
electric shock resulting in death or serious
injury.
When Adjusting Or Making Repairs To Your Generator
• Disconnect the spark pluh 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 for spark with spark plug removed.
WARNING Starter and other rotating parts could
entangle hands, hair, clothing, or accessories
resulting in serious injury.
• NEVER operate generator without protective housing or
covers.
• DO NOT wear loose clothing, jewelry or anything that
could get caught in the starter or other rotating parts.
• Tie up long hair and remove jewelry.
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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 exhaust
gas. DO NOT place generator where exhaust gas (A, Figure
1) could accumulate and enter inside or be drawn into a
potentially occupied building. Ensure exhaust gas is kept
away from any windows, doors, ventilation intakes, or other
openings that can allow exhaust gas to collect in a confined
area. Prevailing winds and air currents should be taken into
consideration when positioning generator.
Fuel Recommendations
Fuel must meet these requirements:
• Clean. fresh, unleaded gasoline
• A minimum of 87 octane/87 AKI (91 RON)
• Gasoline with up to 10% ethanol (gasohol) or up to
15%MTBE (methyl tertiary butyl ether) is acceptable.
NOTICE: Do not use unapproved gasoline, such as E85.
Do not mix oil in gasoline or modify the engine to run on
alternate fuels. Failure to follow will result in damage to the
engine and/or generator and will void the warranty.
To protect the fuel system from gum formation, mix in a
fuel stabilizer when adding fuel. All fuel is not the same. If
you experience starting or performance problems after using
fuel, switch to a different fuel provider or change brands.
This engine is certified to operate on gasoline. The emission
control system for this engine is EM (Engine Modifications).
WARNING Fuel and its vapors are extremely flammable
and explosive which could cause burns,
fire, or explosion resulting in death, serious
injury, and/or property damage.
When Adding or Draining Fuel
• Turn generator engine OFF and let it cool at least 2
minutes before removing fuel cap. Loosen cap slowly to
relieve pressure in tank.
• Fill or drain tank outdoors.
• DO NOT overfill tank. Allow space for fuel expansion.
• If fuel spills, wait until it evaporates before starting
engine.
• Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources.
• Check fuel lines, tank, cap, and fittings frequently for
cracks or leaks. Replace if necessary.
• DO NOT light a cigarette or smoke.
High Altitude
At altitudes over 5,000 feet (1524 meters), a minimum 85
octane / 85 AKI (89 RON) gasoline is acceptable. To remain
emissions compliant, high altitude adjustment is required.
Operation without this adjustment will cause decreased
performance, increased fuel consumption, and increased
emissions.
Operation of the generator at altitudes below 2,500 feet (762
meters) with the high altitude kit is not recommended.
Figure 1
A
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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 cool before turning the vent lever to the “OFF”
position.
Grounding Fastener
The generator neutral is floating, which means that the AC
stator winding is isolated from the grounding fastener and
the AC receptacle ground pins. Therefore, the AC receptacle
ground pins are not functional and electrical devices, such as
a GFCI will not operate.
Figure 2
A
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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 cleaner and oil service.
E - Recoil Starter — Used to start the engine manually.
F - Engine Switch — Set this switch to “ON” before using
recoil starter. Set switch to “OFF” to stop engine. Also
turns fuel valve on and off.
G - Output Indicator — A green LED light comes on when
the generator in working correctly and producing power
at the receptacles.
H - 12 Volt DC Receptacle — Use this receptacle with
battery charge cables to charge a 12 Volt battery. This
receptacle is protected by a push to reset circuit breaker.
J - Grounding Fastener — Consult your local agency having
jurisdiction for grounding requirements in your area.
K - 120 Volt AC, 20 Amp, Duplex Receptacle — May be
used to supply electrical power for the operation of 120
Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting,
appliance, tool, and motor loads.
L - Overload Alarm — A red LED light comes on and
cuts power to the receptacles when the generator is
overloaded.
M - Low Oil Indicator — A yellow LED light comes on when
the oil in the generator drops below a preset level.
N - POWERSMART Switch — Use the switch to turn the
POWERSMART mode on and off.
P - Spark Arrester Screen — Exhaust muffler lowers engine
noise and is equipped with a spark arrester screen.
R - Top Maintenance Cover — Remove to gain access to the
spark plug.
Items Not Shown:
Air Cleaner (behind side maintenance cover) —
Protects engine by filtering dust and debris out of intake
air.
Oil Fill Cap (behind side maintenance cover) — Check
and add engine oil here.
Identification Label — Provides model, revision, and
serial number of generator. Please have these readily
available when calling for assistance.
A
B
C
D
E
F
G
H
J
R
P
N
M
L
K
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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 engine air cleaner and breather filter*
Every 100 Hours or 6 Months
• Clean fuel strainer
• Change engine oil*
• Service spark plug
• Inspect muffler and spark arrester
Every 250 Hours or Annually
• Check valve clearance
*Service more often under dirty or dusty conditions
General Recommendations
Regular maintenance will improve the performance and
extend the life of the generator.
NOTICE: Improper treatment of the generator could damage
it and shorten its life. Never operate generator without
protective housing or covers to assure proper cooling. Some
adjustments will need to be made periodically to properly
maintain the generator.
Generator Maintenance
Generator maintenance consists of keeping the unit clean
and dry. Operate and store the unit in a clean and dry
environment where it will not be exposed to excessive dust,
dirt, moisture, or any corrosive vapors. Cooling air slots in
the generator must not become clogged with snow, leaves, or
any other foreign material.
NOTICE: DO NOT use water or other liquids to clean
generator. Liquids can enter engine fuel system, causing
poor performance and/or failure to occur. In addition, if liquid
enters generator through cooling air slots, some of the liquid
will be retained in voids and cracks of the rotor and stator
winding insulation. Liquid and dirt buildup on the generator
internal windings will eventually decrease the insulation
resistance of these windings.
Cleaning Fuel Strainer
The fuel strainer helps prevent debris from entering the fuel
system.
Clean the fuel strainer as follows:
1. Make sure generator is on a level surface.
2. Remove the fuel cap (A, Figure 3) and fuel strainer (B).
3. Wash fuel strainer in liquid detergent and water.
4. Wipe fuel strainer clean with a clean, dry cloth.
5. Carefully reinstall the fuel strainer and fuel cap.
Figure 3
A
B
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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 for spark with spark plug removed.
Engine Maintenance
Oil
Oil Recommendations
We recommend the use of Briggs & Stratton Warranty
Certified oils for best performance. Other high-quality
detergent oils are acceptable if classified for service SF, SG,
SH, SJ or higher. DO NOT use special additives.
Outdoor temperatures determine the proper oil viscosity for
the engine. Use the chart to select the best viscosity for the
outdoor temperature range expected.
Checking Oil Level / Adding Oil
Oil level should be checked prior to each use or at least every
8 hours of operation. Keep oil level maintained.
1. Make sure generator is on a level surface.
2. Loosen the side maintenance cover screws and remove
the side maintenance cover (Figure 4).
Figure 4
3. Clean area around oil fill and remove oil fill cap.
4. Verify oil is at the point of overflowing at oil fill opening
(Figure 5).
Figure 5
5. If needed, slowly pour oil into oil fill opeinging to the
point of overflowing at oil fill.
6. Replace and tighten oil fill cap.
7. Reinstall the side maintenance cover and hand tighten
the cover screws.
* Below 40°F (4°C) the use of SAE 30 will result in hard starting.
** Above 80°F (27°C) the use of 10W30 may cause increased oil
consumption. Check oil level more frequently.
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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 exposed areas with soap and water.
KEEP OUT OF REACH OF CHILDREN. DON’T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.
Change the oil while the engine is still warm from running, as
follows:
1. Make sure generator is on level surface.
2. Loosen the side maintenance cover screws and remove
the side maintenance cover.
3. Clean area around oil fill and remove oil fill cap.
4. Tip the generator to drain oil from oil fill into a suitable
container, making sure that the unit is tipped towards the
oil filler neck. When the crankcase is empty, return the
generator to the upright position.
5. Slowly pour oil (about 13.5 oz.) into oil fill opening to the
point of overflowing at oil fill cap. DO NOT overfill (Figure 6).
Figure 6
6. Reinstall oil fill cap. Finger tighten cap securely.
7. Wipe up any spilled oil.
8. Reinstall the side maintenance cover and hand tighten
the cover screws.
Service Air Cleaner
The engine will not run properly and may be damaged if it is
run with a dirty air cleaner. Service more often if operating
under dirty or dusty conditions.
1. Loosen the side maintenance cover screws and remove
the side maintenance cover.
2. Loosen air cleaner cover screw (A, Figure 7) and remove
air cleaner cover (B).
3. Carefully remove foam air cleaner (C).
4. Carefully remove breather filter (D).
5. Wash foam air cleaner and breather filter in liquid
detergent and water only. Squeeze dry in a clean cloth.
6. SATURATE foam air cleaner in clean engine oil and
squeeze in a clean cloth to remove excess oil.
7. Reinstall clean or new foam air cleaner inside base.
8. Reinstall clean or new breather filter inside base.
9. Reinstall the air cleaner cover and tighten screw.
10. Reinstall the side maintenance cover and hand tighten
the cover screws.
Figure 7
C
B
A
D
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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 (A, Figure 10) and
reset the spark plug gap to recommended gap if necessary.
Figure 10
6. Replace spark plug if electrodes are pitted, burned, or
porcelain is cracked. Use the recommended replacement
plug.
7. Install spark plug and torque to 180 in. lbs. (20 Nm).
Reinstall spark plug boot.
8. Reinstall top maintenance cover.
9. Reinstall handle and tighten the four handle screws.
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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 area could cause
burns resulting in serious injury.
• DO NOT touch hot parts and AVOID hot exhaust gases.
• Allow equipment to cool before touching.
• DO NOT install the generator closer than 5 feet (1.5m)
from any combustibles or structures with combustible
walls having a fire resistance rating of less than 1 hour.
• Keep at least minimum distances shown in General
Location Guidelines to insure for proper generator cooling
and maintenance clearances.
• It is a violation of California Public Resource Code,
Section 4442, to use or operate the engine on any forest-
covered, brush-covered, or grass-covered land unless
the exhaust system is equipped with a spark arrester, as
defined in Section 4442, maintained in effective working
order. Other states or federal jurisdictions may have
similar laws.
Contact the original equipment manufacturer, retailer, or
dealer to obtain a spark arrester designed for the exhaust
system installed on this engine.
• Replacement parts must be the same and installed in the
same position as the original parts.
Clean and inspect the spark arrester as follows:
1. To remove muffler guard, remove four screws that
connects guard to generator (Figure 11).
Figure 12
Figure 11
2. Remove screw (Figure 12) that attaches spark arrester
screen muffler. Remove spark arrester screen.
3. Inspect screen and obtain a replacement if torn,
perforated, or otherwise damaged. DO NOT use a
defective screen. If screen is not damaged, clean it with
a brush.
4. Reattach screen to muffler. Reattach muffler guard.
Adjust Valve Clearance
NOTE: Check valve clearance while the engine is cold.
1. Turn crankshaft counterclockwise until piston is at top
dead center on the compression stroke. This prevents
the compression release from holding the valves open.
2. Insert a narrow screwdriver or rod into the spark plug as a
gauge, then slowly turn crankshaft counterclockwise until
the piston has moved down the bore by 1/4” (6 mm).
3. Using feeler gauge, check valve clearance. Clearance
should be as listed in Specifications.
4. If not, adjust jam nut until correct clearance is obtained.
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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 out rope from rewind starter as far as it will go.
Then allow rope to retract slightly until the hole in the
pulley and eyelet in the housing are lined up. Securely
clamp the pulley and housing together to prevent the
pulley from spinning.
5. Pull the rope knot out of the pulley. Untie the knot and
then slip rope out of the rewind starter. Remove insert
from rope handle. Untie knot and slip insert and handle
from rope.
6. Carefully release the clamp on the starter and allow the
pulley to slowly unwind until it stops.
7. Remove shoulder screw and retainer plate from pulley.
Lift out pawls and pawl springs.
8. Rotate pulley until rewind springs is disengaged from
anchor tabs in the starter housing. Carefully lift out
pulley with spring. DO NOT remove the spring from the
pulley.
Figure 13
A
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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 spring
assembly.
3. Inspect the starter housing for wear or burrs at the
rope eyelet, the center pivot post, and the anchor tab. If
damage is found, replace the housing.
4. Inspect the drive pawls for wear at the tips or pivot
points. Replace pawls if worn.
5. Inspect the rope for broken or frayed areas. Replace rope
if necessary.
Assemble Rewind Starter
1. Install pulley and spring assembly into starter housing.
Rotate pulley clockwise until slight resistance is felt,
which indicates that the spring has engaged in the
anchor tab.
2. Install pawl springs and pawls. Position retainer plate on
pulley. Ensure that the slots in the retainer fit over the
tabs in the pulley, then install shoulder screw. Torque
screw to 30 in. lb. (3 Nm).
3. While holding retainer, rotate the pulley to extend and
retract the pawls. If they do not move properly, remove
and reinstall the retainer plate.
4. Turn pulley clockwise until the spring is wound tight.
Then allow the pulley to unwind slightly until the hole
in the pulley and the eyelet in the housing are lined
up. Securely clamp the pulley and housing together to
prevent the pulley from spinning.
5. Insert one end of starter rope through the eyelet and
then through hole in pulley. Tie an overhand knot in the
end of rope, then pull rope until knot is seated in pulley,
Trim excess rope if necessary.
6. Slip other end of rope through handle and insert. Tie a
knot in end of rope, then pull rope until knot is seated in
the insert. Trim excess rope if necessary.
7. Quickly burn each end of the rope with an open flame to
prevent swelling and fraying of the weave. Then press
the handle insert into the rope handle.
8. Carefully release the clamp on the starter and allow
the pulley to slowly unwind until the rope is retracted.
Smoothly pull the rope handle several times to ensure
proper operation of the starter assembly.
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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 or fuel hoses
• Cracks or distortion in pump body or base
Fuel Tank
The fuel tank is metal (A, Figure 17) and is not repairable.
Inspect tank for:
• Corrosion
• Leaks
If leaks or other damage are found, replace the tank.
Fuel Hoses
Inspect hoses for:
• Blockage
• Kinks
• Brittleness
• Tears
• Bulges
If any damage is found, replace the hoses (Figure 18).
Figure 18
Figure 16
A
Figure 17
A
Fuel
Filter
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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 (C, Figure 21).
If the fuel valve leaks, it must be replaced as follows:
1. Loosen four screws (Figure 22) on the control panel.
Figure 22
Figure 20
B
Figure 21
C
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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. Set fuel tank aside.
Figure 24
5. Locate fuel valve (F, Figure 25) inside of the generator
enclosure.
6. Remove hoses (G) and loosen screw (H) to remove the
fuel valve.
7. Install a new fuel valve using the above steps in reverse
order.
Fuel Filter
The fuel filter is located inside the fuel tank (See Figure 18)
and can be accessed by removing fuel hose. If fuel is not
flowing properly, remove the filter and clean it with carb
cleaner or other appropriate cleaner.
If fuel will not flow after cleaning, replace the filter.
Figure 25
H
F
G
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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 Residue
If carburetor is suspected to have a fuel leak or blockage,
follow these steps:
1. Loosen the two self-locking screws and remove the side
maintenance cover (Figure 26) and set aside. This will
expose the air filter and carburetor assemblies.
Figure 26
2. Inspect carburetor fuel drain hose (A, Figure 27). If there
is a leak, check to make sure the drain screw (B) is tight
and secured correctly.
Figure 27
A
B
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