Simplicity 4,500 Watt PowerBoss Manual

Parts Manual
Mfg. No: 1648-1
4,500 Watt PowerBoss
Copyright © Briggs & Stratton. All Rights reserved
23-Jul-2021
Table Of Contents
Model Components
Page
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Copyright © Briggs & Stratton. All Rights reserved
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16
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23-Jul-2021
Alternator
Note: Unless noted otherwise, use the standard torque specifications
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Copyright © Briggs & Stratton. All Rights reserved
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Mfg. No: 1648-1
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Alternator
REF NO
PART NO
1
2
186059GS
193623GS
3
4
5
6
7
8
9
10
11
12
13
14
15
200416AGS
186060GS
86308CGS
91825GS
66849GS
22694GS
81917GS
193428AGS
66849AGS
65795GS
200425GS
195180ZGS
65791GS
QTY
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Copyright © Briggs & Stratton. All Rights reserved
DESCRIPTION
ADAPTER, Mounting, Alternator
ROTOR
-(Includes Item 15)
STATOR
RBC, with O-Ring (p/n 189197GS)
HHCS, M6 - 1.0 x 130 SEMS
ASSY, Holder, Rectifier/Brush
TAPTITE, M5 - 0.8 x 16
RECEPTACLE, 6 pin
PIN, Roll, 4mm x 10
ASSY, Wire, Ground
TAPTITE, M5 - 0.8 x 20
RECTIFIER, Battery Charge
HARNESS, Wire, Power
ASSY, Wire
BEARING
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Control Panel
Note: Unless noted otherwise, use the standard torque specifications
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Copyright © Briggs & Stratton. All Rights reserved
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Control Panel
REF NO
PART NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
B189250GS
189251GS
82538GS
90418GS
189520GS
82881GS
189737GS
43182GS
51714GS
75207GS
23365GS
43437GS
38150GS
22264GS
51715GS
80409GS
189165GS
189367GS
84028GS
87962GS
22694GS
82308GS
189502GS
QTY
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Copyright © Briggs & Stratton. All Rights reserved
DESCRIPTION
COVER, Lid, Control Panel
CONTROL PANEL, Back, Plastic
SWITCH, Rocker
OUTLET, 12VDC, Snap
SCREW, Self Tapping, STC 3x10
LOCK WASHER, Internal
HOUR METER
WASHER, Lock, M3
NUT, M3 - 0.5
CIRCUIT BREAKER, 20A
WASHER, Shakeproof, Internal #8
OUTLET, 120/240, 30A
WASHER, Flat, #8
WASHER, Lock, #8 - M4
NUT, M4 - 0.7
OUTLET, Duplex, 20A
NUT, Palnut, Pushnut, 5/32
BOARD, Idle Control
TRANSFORMER, Idle Control
BREAKER, Circuit, 10A, 12V
HOUSING, Receptacle
SCREW, Self Tapping, STC 3x18
HARNESS, Idle Control
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Main Unit
Note: Unless noted otherwise, use the standard torque specifications
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Mfg. No: 1648-1
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Main Unit
REF NO
PART NO
1
2
4
5
B189252GS
194150GS
190220GS
~NSP
6
-----
8
9
96796GS
-----
10
11
12
190274DGS
187365AGS
-----
14
15
200082GS
-----
16
-----
17
-----
18
19
20
21
22
23
24
25
26
27
56893GS
55934GGS
B4986GS
194153GS
86494GS
86292GS
B189434GS
191190GS
74908GS
-----
QTY
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28
-----
29
31
32
189377GS
196830GS
-----
34
35
37
40
195422GS
791745
B2153GS
194398GS
41
44
192980GS
197443GS
45
48
50
51
52
55
58
B4363GS
195373GS
188333GS
194799GS
93826GS
197798GS
189249GS
60
J189384GS
Copyright © Briggs & Stratton. All Rights reserved
DESCRIPTION
KIT, Cradle
KIT, Vibration Mount
ADAPTER, Engine
ASSY, Alternator
-(see "Alternator")
NUT, Hex M8 - 1.25
-(Purchase locally)
WASHER, 8.4 x 22.2 x 3
WASHER, Flat, 5/16 - M8
-(Purchase locally)
SBHCS, 3/8 - 16 x 7/8
HHCS, 5/16 - 24 x 7.13
HHCS, M8 - 1.25 x 25
-(Purchase locally)
CONNECTOR
WASHER, Lock 5/16 - M8
-(Purchase locally)
HHCS, M8 - 1.25 x 35
-(Purchase locally)
HHCS, M6 - 1.0 x 30
-(Purchase locally)
CRIMPTITE, 10-24 x 1/2"
CLAMP, Hose
DECAL, Ground
KIT, Vibration Mount
SCREW, Wing M6 - 1.0 x 16
SCREW, 10 - 16 x 3/4, Self Drill
COVER, Engine
CAP
SCREW, M5-0.8 x 10, Taptite
HHCS, 1/4 - 20 x 1
-(Purchase locally)
FLAT WASHER, 1/4 - M6
-(Purchase locally)
WELLNUT, 1/4 - 20
DECAL, Exhaust Warning
LOCK WASHER, 1/4
-(Purchase locally)
COVER, RBC, Plastic w/Cap
LINE, Fuel
SCREW, Self Drill, 12 - 14 x 7/8
KIT, Fuel Tank Hardware
-(Includes Qty of 4)
KIT, Fuel Valve
ASSY, Fuel Tank
-(Includes Items 41, 50, 51 & 52)
CAP, Fuel Gauge
WIRE, Ground
DECAL, Instructions, Fuel Level
DECAL, Danger
DECAL, Start Instructions
DECAL, Fuel Shut-Off
ASSY, Control Panel
-(see "Control Panel")
HEAT SHIELD, Muffler
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Main Unit
Note: Unless noted otherwise, use the standard torque specifications
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Mfg. No: 1648-1
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Main Unit
REF NO
PART NO
900
-----
QTY
BB3061BGS
B1464GS
200167GS
65787GS
200719GS
100031
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Copyright © Briggs & Stratton. All Rights reserved
DESCRIPTION
ENGINE, Honda
-Contact Engine Manufacturer
OIL BOTTLE
-Not Illustrated
MANUAL, Engine
-Not Illustrated
MANUAL, Operator's
-Not Illustrated
CABLE, Battery Charge
-Not Illustrated
KIT, Decals Srv
-Not Illustrated
STABILIZER, Fuel
-Optional Accessories
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Wheel Kit
Note: Unless noted otherwise, use the standard torque specifications
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Mfg. No: 1648-1
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Wheel Kit
REF NO
PART NO
1
B193200GS
2
3
4
5
B4966GS
191267KGS
191265GS
-----
6
195686GS
7
8
87841GS
-----
9
10
67989GS
-----
11
-----
12
-----
13
-----
14
-----
15
16
17
198669GS
B4135GS
77395GS
QTY
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Copyright © Briggs & Stratton. All Rights reserved
DESCRIPTION
ASSY, Handle
-(Includes Item 15)
WHEEL
AXLE, 5/8" x 24.80"
E-RING
HHCS, M8 - 1.25 x 45 Lg.
-(Purchase locally)
ASSY, Support
-(Includes Item 7)
VIB MOUNT
HHCS, M6 - 1.0 x 16
-(Purchase locally)
NUT, M8 Flange Serrated
WASHER, Flat 5/8
-(Purchase locally)
HHCS, M8 - 1.25 x 20 Lg.
-(Purchase locally)
WASHER, Flat, 5/16-M8
-(Purchase locally)
NUT, M8 - 1.25 Nylok
-(Purchase locally)
WASHER, 1.2 x .0346 x 0.03, Nyln
-(Purchase locally)
GRIP
PIN, with Lanyard
NUT, M6 Flange Lock
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Wiring Diagram
Note: Unless noted otherwise, use the standard torque specifications
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Wiring Diagram
REF NO
PART NO
---
---------
QTY
F
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Copyright © Briggs & Stratton. All Rights reserved
DESCRIPTION
Wiring Diagram only
WARNING - Generator Voltage Could Cause Electrical Shock or Burn Resulting
in Death Or Serious Injury. To Avoid Electrical Shock Or Burn Hazard, Please
Refer Service To Qualified Personnel.
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Wiring Schematic
Note: Unless noted otherwise, use the standard torque specifications
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Mfg. No: 1648-1
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Wiring Schematic
REF NO
PART NO
---
---------
QTY
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Copyright © Briggs & Stratton. All Rights reserved
DESCRIPTION
Wiring Schematic Only
WARNING - Generator Voltage Could Cause Electrical Shock or Burn Resulting
in Death Or Serious Injury. To Avoid Electrical Shock Or Burn Hazard, Please
Refer Service To Qualified Personnel.
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Hardware Identification & Torque Specifications
Torque Specification Chart
Torque Specification Chart
FOR STANDARD METRIC MACHINE HARDWARE (Tolerance ± 20%)
Property
Class
5.6
8.8
Class 5.6
Class 8.8
in/lbs
Size Of
Hardware ft/lbs
M3
M4
M5
M6
M7
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
5.88
13.44
26.4
44.64
5.2
7.7
15
26
42
64
89
126
169
217
320
435
590
759
988
10.9
Nm.
Nm.
in/lbs
ft/lbs
.56
1.28
2.50
4.3
7.1
10.5
21
36
58
88
121
171
230
295
435
590
800
1030
1340
13.44
30.72
60.96
7.3
12.1
17.7
35
61
101
147
202
290
390
497
733
995
1349
1740
2249
1.28 19.2
2.90 43.44
5.75 5.97
9.9 10.3
16.5 16.9
25
24
50
48
83 86.2
136
132
210
200
287
275
405
390
559
530
708
375
995 1032
1350 1401
1830 1902
2360 2441
3050 3163
SAE Grade 2
Class 12.9
Size Of
Hardware
Nm.
in/lbs
ft/lbs
Nm.
1.80
4.10
8.10
14
23
34
67
117
185
285
390
550
745
960
1400
1900
2580
3310
4290
22.92
52.56
7.15
12.1
19.9
29
59
103
162
250
346
486
656
840
1239
1681
2278
2935
3798
2.15
4.95
9.7
16.5
27
40
81
140
220
340
470
660
890
1140
1680
2280
3090
3980
5150
20
10
30
40
50
60
80
70
Body Length
Screw, M8- 1.25 x 25
Thread
Diameter (mm)
Threads
Inside
Diameter (in) per inch
1/4
1/2
3/4
1
2.1
2.3
3.1
3.5
7.6
8.6
15.0
16.3
27.2
31.3
40.8
47.6
68.0
74.8
88.4
102.0
122.4
136
217.6
244.8
190.4
210.8
299.2
326.4
Body
Length (mm)
Body
Length (in)
in/lbs
ft/lbs
30
31
43
49
8
10
17
19
30
35
50
55
75
90
110
120
150
180
260
300
400
440
580
640
SAE Grade 8
Nm.
in/lbs
ft/lbs
Nm.
3.4
3.5
4.9
5.5
10.9
13.6
23.1
25.8
40.8
47.6
68.0
74.8
102.0
122.4
149.6
163.2
204.0
244.8
353.6
408.0
544.0
598.4
788.8
870.4
41
43
60
68
12
14
25
29
45
50
70
80
110
120
150
170
220
240
386
420
600
660
900
1,000
4.6
4.9
6.8
7.7
16.3
19.0
34.0
34.0
61.2
68.0
95.2
108.8
149.6
163.2
204.0
231.2
299.2
326.4
525.0
571.2
816.0
897.6
1,244.0
1,360.0
NOTES
1. These torque values are to be used for all hardware
excluding: locknuts, self-tapping screws, thread forming
screws, sheet metal screws and socket head setscrews.
2. Recommended seating torque values for locknuts:
a. for prevailing torque locknuts - use 65% of grade 5
torques.
b. for flange whizlock nuts and screws - use 135% of
grade 5 torques.
3. Unless otherwise noted on assembly drawings, all torque
values must meet this specification.
Screw, 1/2- 16 x 2
Nut, 1/2-16
0
Distance between
threads (mm)
Threads
per inch
Thread
Diameter (mm)
Body
Diameter
19
20
27
31
66
76
11
12
20
23
30
35
50
55
65
75
90
100
160
180
140
155
220
240
SAE Grade 5
Nm.
100
90
Body
Diameter
Nut, M8
in/lbs
ft/lbs
8-32
8-36
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
1-12
The guides and ruler furnished below are designed to
help you select the appropriate hardware.
0
No
Marks
Hardware
Grade
12.9
Class 10.9
in/lbs
ft/lbs
FOR STANDARD MACHINE HARDWARE (Tolerance ± 20%)
1/4
1/2
3/4
2
1/4
1/2
3/4
3
1/4
1/2
3/4
4
Common Hardware Types
Hex Head Capscrew
Washer
Standard Hardware Sizing
When a washer or nut is identified as 1/2” (M8), this is
the Nominal size, meaning the inside diameter is 1/2 inch
(8mm metric thread diameter); if a second number is present
it represents the threads per inch (distance between threads).
When bolt or capscrew is identified as 1/2 - 16 x 2” (M8 - 1.25 x 50),
this means the Nominal size, or body diameter is 1/2 inch (8mm
metric thread diameter), the second number,16, represents the
threads per inch, (distance between threads). The final number
is the body length of the bolt or screw, 2 inches (50mm).
Lockwasher
Carriage Bolt
Hex Nut
Wrench & Fastener Size Guide
1/4” Bolt or Nut
Wrench—7/16”
5/16” Bolt or Nut
Wrench—1/2”
3/8” Bolt or Nut
Wrench—9/16”
M6 Bolt or Nut
Wrench—10mm
M8 Bolt or Nut
Wrench—13mm
M10 Bolt or Nut
Wrench—17mm
7/16” Bolt or Nut
1/2” Bolt or Nut
Wrench (Bolt)—5/8”
Wrench—3/4”
Wrench (Nut)—11/16”
M12 Bolt or Nut
Wrench—19mm
M14 Bolt or Nut
Wrench—22 mm
Copyright © Briggs & Stratton. All Rights reserved
23-Jul-2021

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