Alternator Identification Briggs & Stratton Engines Are Equipped with a Number of Different Alternator Systems to Meet the Require- Ments of Equipment Manufacturers

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Alternator Identification Briggs & Stratton engines are equipped with a number of different alternator systems to meet the requirements of equipment manufacturers. For example, a large lawn tractor with accessories may require a 16 amp regulated system, whereas a snow thrower with a single headlight requires an AC Only system. Knowing the type of alternator system an engine is equipped with is important, particularly when an engine is being replaced. Briggs & Stratton alternator systems are easily identified by the color of the stator output wire(s) and the connector.

Stator Output Wire(s) And Connector (typical)

AC Only DC Only

ONE BLACK LEAD FROM ENGINE ONE RED LEAD (STATOR) FROM ENGINE (STATOR ) RED CONNECTOR

TO EQUIPMENT DIODE HARNESS WHITE CONNECTOR OUTPUT LEAD TO EQUIPMENT HARNESS

• 14 Volts AC for lighting circuit. • 3ampDCunregulatedforchargingbattery. • One black lead from stator. • One red lead from stator. • White connector output lead. • Diode encased at connector. • Red connector output lead.

1 Dual Circuit BLACK LEAD 10 or 16 amp Regulated RED LEAD AC OUTPUT DC OUTPUT TO EQUIPMENT HARNESS RED AND BLACK LEADS FROM ENGINE RED CONNECTOR (STATOR) OUTPUT LEAD

DC CHARGING CIRCUIT TWO BLACK LEADS RED LEAD ONE RED FROM ENGINE LEAD (STATOR)

WHITE TO EQUIPMENT CONNECTOR HARNESS WHITE LEAD AC FOR LIGHTS • 3 amp DC unregulated for charging battery (ONE red lead from stator). • 14 Volts AC for lighting circuit YELLOW REGULATOR TWO YELLOW LEADS CONNECTOR (ONE black lead from stator). RECTIFIER • Diode encased at connector. White connector with two pin terminals. • • 10 or 16 amp DC regulated for charging battery. • Alternatoroutputisdeterminedbytheflywheel alternator magnet size. Tri-Circuit • 10 and 16 amp system use the same stator, color coding and regulator-rectifier. ONE BLACK LEAD FROM ENGINE • Two black leads from stator. (STATOR) TO EQUIPMENT • Yellow connector with two pin terminals. HARNESS 5 AMPS DC (-) TWO DIODES ENCASED Two yellow leads to regulator-rectifier. TO LIGHTS IN WIRE HARNESS • WHITE LEAD • One red lead from regulator-rectifier to red connector output lead.

GREEN RED LEAD 5 AMPS DC (+) CONNECTOR TO BATTERY AND CLUTCH CIRCUIT 493219 Regulator/Rectifier Used With Charge Indicator Circuit • 10 amp AC. • One black lead from stator. TO EQUIPMENT Green connector. HARNESS RED WIRE AND RAISED • RIB INDICATES DC OUTPUT • Two diodes encased in wire harness. • Red and white output leads. BLUE WIRE CHARGING INDICATOR

WHITE CONNECTOR TO ONE BLACK LEAD 5 or 9 amp Regulated EQUIPMENT FROM ENGINE HARNESS (STATOR) RED CONNECTOR

GREEN CONNECTOR YELLOW WIRE TWO YELLOW 493219 REGULATOR LEADS YELLOW RECTIFIER CONNECTOR

REGULATOR RECTIFIER

• 5 or 9 amp DC regulated for charging battery. • Uses same stator as 10 and 16 amp system. • Alternator output (5 or 9 amp) is determined by • DC output the same as 10 or 16 amp system. flywheel alternator magnet size. • Charge indicator light and wiring supplied by • Uses same stator as Tri-Circuit system. equipment manufacturer. • One black lead from stator. • Red DC output wire to white connector. • Green connector. • Blue charge indicator wire to white connector.

2 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 theequipment tofunction, 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.

Replacing Briggs & Stratton Engines When replacing an older Briggs & Stratton engine on apiece ofequipment witha newerBriggs &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 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, Tri-Circuit 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.

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

* 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)

3 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 393362 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 EQUIPMENT HARNESS DUAL CIRCUIT CONNECTOR (WHITE) (FROM ENGINE) 393362 HARNESS AC BLACK

DC RED SPLICE 393537 RIB RIB CONNECTOR (GREEN)

2. Original engine equipped with DC Only alternator. Replacement engine equipped with Dual Circuit alternator.

Modify 393362 harness supplied with replacement engine by removingwhite ACwire. Then,splice 393537 connector into red DC wire and connect to equipment harness.

DUAL CIRCUIT CONNECTOR EQUIPMENT (FROM ENGINE) 393362 DC WIRE HARNESS (RED) HARNESS

AC BLACK

DC RED

RIB SPLICE 393537 RIB CONNECTOR (GREEN)

4 3. Original engine equipped with Dual Circuit alternator. Replacement engine equipped with 5, 9, 10 or 16 amp regulated system.

Modify 393422 harness supplied with replacement engine by splicing in 399916 connector assembly. Connect to equipment harness.

399916 CONNECTOR ASSEMBLY EQUIPMENT OUTPUT CONNECTOR HARNESS FROM REGULATOR SPLICE

393422 RIB RIB HARNESS

4. Original engine equipped with Tri-Circuit alternator. Replacement engine equipped with 5, 9, 10 or 16 amp regulated system.

Modify 393422 harness supplied with replacement engine by splicing into charging circuit wireand lighting circuit wire in equipment harness. NOTE:THE DIODESMUST BEREMOVED FROMTHE EQUIPMENT HARNESS.

Diodes Must Be Removed From Equipment Harness

OUTPUT CONNECTOR FROM REGULATOR SPLICE LIGHTING CIRCUIT WIRE

EQUIPMENT HARNESS

393422 HARNESS CHARGING CIRCUIT WIRE

5 5. Original engine equipped with Dual Circuit alternator. Replacement engine equipped Tri-Circuit alternator.

Discard 392606 diode harness supplied with new engine. Install 491546 regulator/rectifier. Add 393422 harness and modify by splicing in 399916 connector assembly. Connect to equipment harness.

399916 CONNECTOR OUTPUT CONNECTOR ASSEMBLY FROM ALTERNATOR SPLICE

393422 RIB HARNESS RIB EQUIPMENT HARNESS

491546 REGULATOR/RECTIFIER

6. Original engine equipped with 5 amp regulated system. Replacement engine equipped with Tri-Circuit alternator.

Discard 392606 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. 6 Briggs & Stratton Engine Replacing Engine Of Another Manufacturer When replacing the engine of another manufacturer with a Briggs & Stratton engine, the equipment requirements must be known so that the replacement alternator system has the same output as the original system provided. Often the equipment wiring harness is not compatible with the Briggs & Stratton alternator output harness. To create a compatible system it may be necessary to modify the the equipment wiring harness. To do this a wiring diagram for the equipment is essential. The original keyswitch may also create a problem. Even though the keyswitch harness connectors appear to be identical, there are internal differences to keyswitches. Therefore it is necessary to have a diagram of the keyswitch showing the terminal positions and their functions. For example, see the 5 terminal switch diagrams in Figure 1 and Figure 2. The keyswitch in Figure 1 is compatible with all Briggs & Stratton alternators. Note in Figure 2, that when the “brand X” keyswitch is in the START position there is no battery voltage available to the #2 switch terminal. Consequently, if the replacement Briggs & Stratton engine was equipped with a carburetor solenoid, it would not function. This is why it is important to have a diagram of the keyswitch when replacing engines, or replace the keyswitch with one that is compatible with all Briggs & Stratton alternator systems. NOTE: The 5 terminal Briggs & Stratton keyswitch, part no. 490066, shown in Fig. 1 has been replaced by a 6 terminal keyswitch, part no. 493625. The additional terminal provides a direct connection for the charging lead at the keyswitch. B & S Switch Terminal Positions Brand X Switch Terminal Positions Terminal Terminal No. Function No Function 1 Ground (Used only with insulated panel) 1 Accessory 2 To Carburetor Solenoid. 2 To Stop Switch Terminal On Engine (Ground) 3 To Stop Switch Terminal On Engine 3 To Regulator (Charging) 4 To Solenoid (tab terminal) 4 To Solenoid (tab terminal) 5 To Battery (battery terminal on solenoid) 5 To Battery (battery terminal on solenoid)

L M L M M R M R 2 3 2 3 2 3 2 3 4 S 4 S 4 S 4 S 1 5 1 5 1 5 1 5 G B G B A B A B

OFF RUN OFF RUN

L M M R 2 3 2 3 4 S 4 S 1 5 1 5 G B A B

START START

Fig. 1 Fig. 2 It is not possible to show all of the wiring diagrams or keyswitch combinations that are used by equipment manufacturers. However, the following wiring diagrams for the most popular Briggs & Stratton engines may be used as a guide whenreplacing anengine. Thewiring diagramsshow thetype of keyswitch that is compatible with the alternator system shown.

7 Typical Dual Circuit Alternator Wiring Diagram 5 Pole Switch -- Briggs & Stratton Part No. 490066

ANTI-AFTERFIRE STOP SOLENOID SWITCH ALTERNATOR TERMINAL

DIODE KEY SWITCH

2 3 4 1 5 AC OUTPUT WIRE DC OUTPUT WIRE

+ AMMETER SOLENOID TAB TERMINAL HEADLIGHTS -- HEADLIGHT BATTERY SWITCH TERMINAL STARTER TERMINAL

SOLENOID

- +

STARTER MOTOR

12 VOLT BATTERY

Key Switch Test

Switch Position Continuity Terminal No. Function 1. OFF *1 + 3 1 Ground (Used only with insulated panel) 2. RUN 2 + 5 2 To Carburetor Solenoid. 3. START 2 + 4 + 5 3 To Stop Switch Terminal On Engine 4 To Solenoid (tab terminal) * Terminal 1 Grounded Internally 5 To Battery (battery terminal on solenoid) To Key Switch Case

8 Typical Dual Circuit Alternator Wiring Diagram 6 Pole Switch -- Briggs & Stratton Part No. 493625

ANTI-AFTERFIRE STOP SOLENOID SWITCH ALTERNATOR TERMINAL

DIODE KEY SWITCH

2 3

4 AC OUTPUT 1 5 WIRE DC OUTPUT WIRE 6 Ammeter + -- Ammeter (optional) SOLENOID TAB HEADLIGHTS -- + TERMINAL HEADLIGHT SWITCH BATTERY STARTER TERMINAL TERMINAL

SOLENOID

- +

STARTER MOTOR

12 VOLT BATTERY

With ammeter shown in optional position, note that -- and + symbols are Key Switch Test reversed. The + symbol must always be connected to the alternator side. Switch Position Continuity Terminal No. Function 1. OFF *1 + 3 + 6 1 To Ground (used only with insulated panel) 2. RUN 2 + 5 + 6 2 To Carburetor Solenoid. 3. START 2 + 4 + 5 3 To Stop Switch Terminal On Engine 4 To Solenoid (tab terminal) *Terminal 1 Grounded Internally 5 To Battery (battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output)

9 Typical 16 amp Regulated Alternator Wiring Diagram 5 Pole Switch -- Briggs & Stratton Part No. 490066

ANTI-AFTERFIRE STOP SOLENOID SWITCH TERMINAL

ALTERNATOR KEY SWITCH

2 3

AC OUTPUT WIRE 4

DC OUTPUT 1 5 WIRE

REGULATOR RECTIFIER + AMMETER SOLENOID TAB -- TERMINAL BATTERY TERMINAL STARTER TERMINAL

HEADLIGHTS HEADLIGHT SOLENOID SWITCH

- +

STARTER MOTOR

12 VOLT BATTERY

Key Switch Test

Switch Position Continuity Terminal No. Function 1. OFF *1 + 3 1 Ground (Used only with insulated panel) 2. RUN 2 + 5 2 To Carburetor Solenoid. 3. START 2 + 4 + 5 3 To Stop Switch Terminal On Engine * Terminal 1 Grounded Internally 4 To Solenoid (tab terminal) To Key Switch Case 5 To Battery (battery terminal on solenoid)

10 Typical 16 amp Regulated Alternator Wiring Diagram 6 Pole Switch -- Briggs & Stratton Part No. 493625

STOP ANTI-AFTERFIRE SWITCH SOLENOID TERMINAL

ALTERNATOR

KEY SWITCH

2 3

AC OUTPUT WIRE 4

DC OUTPUT 1 5 WIRE 6 AMMETER + -- REGULATOR RECTIFIER Ammeter (optional) SOLENOID TAB -- + TERMINAL

BATTERY TERMINAL STARTER TERMINAL

HEADLIGHTS SOLENOID HEADLIGHT SWITCH

- +

STARTER MOTOR

12 VOLT BATTERY

With ammeter shown in optional position, note that -- and + symbols are Key Switch Test reversed. The + symbol must always be connected to the alternator side. Switch Position Continuity Terminal No. Function 1. OFF *1 + 3 + 6 1 To Ground (used only with insulated panel) 2. RUN 2 + 5 + 6 2 To Carburetor Solenoid. 3. START 2 + 4 + 5 3 To Stop Switch Terminal On Engine 4 To Solenoid (tab terminal) * Terminal 1 Grounded Internally 5 To Battery (battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output)

11 Typical 16 amp Regulated Alternator Wiring Diagram With Charge Indicator Light 6 Pole Switch -- Briggs & Stratton Part No. 493625

ALTERNATOR ANTI-AFTERFIRE STOP SOLENOID SWITCH TERMINAL

AC OUTPUT CHARGE 2 3 WIRE INDICATOR LIGHT 4 1 5

BLUE WIRE 6

AMMETER REGULATOR RECTIFIER + --

RAISED RIB SOLENOID TAB RED WIRE Ammeter TERMINAL DC OUTPUT (optional) BATTERY -- + TERMINAL STARTER TERMINAL

HEADLIGHTS SOLENOID HEADLIGHT SWITCH

- +

Starter Motor

12 VOLT BATTERY

Key Switch Test With ammeter shown in optional position, note that -- and + symbols are reversed. The + symbol must always be connected to the alternator side. Switch Position Continuity Terminal No. Function 1. OFF *1 + 3 + 6 1 To Ground (used only with insulated panel) 2. RUN 2 + 5 + 6 2 To Carburetor Solenoid. 3. START 2 + 4 + 5 3 To Stop Switch Terminal On Engine 4 To Solenoid (tab terminal) * Terminal 1 Grounded Internally 5 To Battery (battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output)

12 Typical 5/9 amp Regulated Alternator Wiring Diagram 6 Pole Switch -- Briggs & Stratton Part No. 493625

TRI--CIRCUIT STATOR

STOP ANTI-AFTERFIRE SWITCH SOLENOID TERMINAL

Alternator KEY SWITCH

2 3

4 AC OUTPUT WIRE DC OUTPUT WIRE 1 5

AMMETER REGULATOR RECTIFIER + -- Ammeter SOLENOID TAB (optional) TERMINAL BATTERY -- + TERMINAL STARTER TERMINAL

HEADLIGHTS HEADLIGHT SOLENOID SWITCH

- +

STARTER MOTOR

12 VOLT BATTERY

With ammeter shown in optional position, note that -- and + symbols are Key Switch Test reversed. The + symbol must always be connected to the alternator side. Switch Position Continuity Terminal No. Function 1. OFF *1 + 3 + 6 1 To Ground (used only with insulated panel) 2. RUN 2 + 5 + 6 2 To Carburetor Solenoid. 3. START 2 + 4 + 5 3 To Stop Switch Terminal On Engine 4 To Solenoid (tab terminal) * Terminal 1 Grounded Internally 5 To Battery (battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output)

13 Typical 5/9 amp Regulated Alternator Wiring Diagram 6 Pole Switch -- Briggs & Stratton Part No. 493625

TRI--CIRCUIT STATOR

STOP ANTI-AFTERFIRE SWITCH SOLENOID TERMINAL

Alternator KEY SWITCH

2 3

4 AC OUTPUT WIRE DC OUTPUT WIRE 1 5

AMMETER REGULATOR RECTIFIER + -- Ammeter SOLENOID TAB (optional) TERMINAL BATTERY -- + TERMINAL STARTER TERMINAL

HEADLIGHTS HEADLIGHT SOLENOID SWITCH

- +

STARTER MOTOR

12 VOLT BATTERY

With ammeter shown in optional position, note that -- and + symbols are Key Switch Test reversed. The + symbol must always be connected to the alternator side. Switch Position Continuity Terminal No. Function 1. OFF *1 + 3 + 6 1 To Ground (used only with insulated panel) 2. RUN 2 + 5 + 6 2 To Carburetor Solenoid. 3. START 2 + 4 + 5 3 To Stop Switch Terminal On Engine 4 To Solenoid (tab terminal) * Terminal 1 Grounded Internally 5 To Battery (battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output)

13 Typical Tri-Circuit Alternator Wiring Diagram 6 Pole Switch -- Briggs & Stratton Part No. 493625 TRI--CIRCUIT STATOR

STOP ANTI-AFTERFIRE SWITCH AC OUTPUT SOLENOID TERMINAL WIRE ALTERNATOR

KEY SWITCH

2 3

-- DC OUTPUT DC OUTPUT WIRE + 4 WIRE 1 5 HEADLIGHT SWITCH 6 AMMETER + --

Ammeter SOLENOID TAB (optional) TERMINAL HEADLIGHTS BATTERY -- + TERMINAL STARTER CLUTCH TERMINAL SWITCH

SOLENOID

ELECTRIC CLUTCH

- + STARTER MOTOR

12 VOLT BATTERY

With ammeter shown in optional position, note that -- and + symbols are Key Switch Test reversed. The + symbol must always be connected to the alternator side. Switch Position Continuity Terminal No. Function 1. OFF *1 + 3 + 6 1 To Ground (used only with insulated panel) 2. RUN 2 + 5 + 6 2 To Carburetor Solenoid. 3. START 2 + 4 + 5 3 To Stop Switch Terminal On Engine 4 To Solenoid (tab terminal) * Terminal 1 Grounded Internally 5 To Battery (battery terminal on solenoid) To Key Switch Case 6 To Alternator (DC Output)

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