Reproduction. Not for ADVANCE PRODUCT SERVICE INFORMATION INFORMATION BULLETIN NO: 36 DATE: 11/27/02 SUBJECT: POWERLINK SYSTEM

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ADVANCE PRODUCT SERVICE INFORMATION INFORMATION BULLETIN NO: 36 DATE: 11/27/02 SUBJECT: POWERLINK SYSTEM FILE IN: INTEK & VANGUARD REPAIR MANUAL GFCI Inverter Stator POWERLINK Harness Reset ON OFF

1 ADVANCE PRODUCT SERVICE INFORMATION INFORMATION BULLETIN NO: 36 DATE: 11/27/02 SUBJECT: POWERLINK SYSTEM FILE IN: INTEK & VANGUARD REPAIR MANUAL GFCI Inverter Stator POWERLINK Harness Reset ON OFF Switch The POWERLINK system is an auxiliary on-board generator system designed for riding tractors that utilize the INTEK or Vanguard V-Twin engines. It provides 60Hz 120VAC to a Ground Fault Circuit Interrupter (GFCI) receptacle that is supplied by the Original Equipment Manufacturer (OEM). It operates power tools such as edger's, trimmers and other electrical devices. The POWERLINK system has safety features to protect the system and the operator.the POWERLINK system will not function unless the parking brake is engaged on the tractor The electrical output of the POWERLINK system will shut down at any overload caused by temperature or a system overload. Operating at loads above 1000 watts continuously may trigger the POWERLINK system to reset and halt the electrical output needed to power the load. On an overload, the manual reset switch (ON-OFF), located on the tractor, opens and disconnects electrical power to the GFCI receptacle system. Once reset, operating power is returned. If the system continually trips, causing the operator to reset, increase engine speed. If engine is running at top speed and the system is still tripping, the system is being overloaded. Decrease the load. If power does not resume after reset, it may be a thermal overload. Wait 15 minutes before actuating the reset. Prior to connecting any electrical device, ensure compatibility of operating voltage and frequency requirement. Select the engine speed that will power the electrical device satisfactorily without triggering the POWERLINK reset. The electrical operating output will also cease if there is a ground fault. The GFCI receptacle will trip to protect the operator.

POWERLINK OPERATING INSTRUCTIONS Prior to connecting any electrical device, ensure compatibility of operating voltage and frequency requirement.

If using more than one electrical device, plug-in and start the higher rated load first.

2 POWERLINK OPERATING INSTRUCTIONS Prior to connecting any electrical device, ensure compatibility of operating voltage and frequency requirement. It is recommended that all electrical devices and extension cords plugged into the GFCI receptacle have a three-prong terminal. If using more than one electrical device, plug-in and start the higher rated load first. WARNING The POWERLINK On-Board Generator System produces electricity that could result in death, serious injury and/or property damage if precautions are not followed. Never handle any kind of electrical cord or device while standing in water, or barefoot, or while hands are wet. Do not operate unit: In rain If electrical cord or device, which is plugged into the GFCI receptacle over heats. If electrical output is lost. If flame, spark or smoke is observed while unit is running. Maintain and use proper sized electrical cord sets and extension cords per electrical device specification. Use cords rated for no less than 15 amps. Use cords that are in good condition. Never use worn, bare, frayed or otherwise damaged cord sets. Avoid contact with bare wires, terminals and damaged cords. Keep extension cord lengths at minimum possible length. Long extension cords draw additional power. 1. Start the engine and set the desired engine speed. 2. LOCK the parking brake. If brake is unlocked, the POWERLINK system will not operate. 3. Actuate the POWERLINK reset switch. Move the reset switch to the OFF position and then return it to the ON position. 4. Plug the electrical device into the GFCI receptacle and start device. 5. Any time the engine stops, for any reason, the POWERLINK reset switch must be actuated. Follow the steps outlined above. Resetting the POWERLINK System 1. Turn off any device or appliance that was in use prior to the loss of electrical operating power. 2. Verify that the RESET button on GFCI receptacle has not been tripped. 3. The engine must be running and the parking brake MUST be set. 4. Actuate the POWERLINK reset switch. Move the reset switch to the OFF position and then return it to the ON position. For the operator's safety, there is a two second delay in power to the GFCI receptacle after reset. TESTING GFCI OPERATION The GFCI is supplied by the equipment manufacture. To ensure proper operation of the GFCI receptacle it should be tested once a month. 1. Have the POWERLINK system running and the power reset switch ON 2. Plug in a trouble light or radio for verification that electrical power is present. 3. Press the GFCI TEST button in order to trip the system and stop the flow of electricity. 4. If the power goes off, the GFCI is working properly. To restore power, press the RESET button. 5. If the device is still being powered, the GFCI is not working properly. And must be replaced. Use only the GFCI recommended by the equipment manufacturer. Note: If the GFCI requires resetting frequently and there is no problem with the electrical device, the GFCI should be tested. See Test GFCI.

TESTING THE POWERLINK SYSTEM If a problem occurs and the POWERLINK system is suspect, it is important to follow the test procedure exactly in the order shown to isolate the faulty component. 1.

Check alternator output. The following tools are required to test the POWERLINK system. Digital multimeter; Tool #19464. POWERLINK Test Box, Tool#19528. Torx Driver, Tool #19445.

To verify that there is continuity between the inverter case and the engine frame, connect the leads of the multi-meter between the two. If continuity exists, the meter will make a continuous tone.

3 TESTING THE POWERLINK SYSTEM If a problem occurs and the POWERLINK system is suspect, it is important to follow the test procedure exactly in the order shown to isolate the faulty component. 1. Test POWERLINK electrical system ground continuity 2. Test GFCI. 3. Test interlock switch for parking brake. 4. Test POWERLINK reset (ON-OFF) switch on tractor. 5. Check inline fuse. 6. Check alternator output. The following tools are required to test the POWERLINK system. Digital multimeter; Tool # POWERLINK Test Box, Tool# Torx Driver, Tool # Test POWERLINK Electrical System Ground Continuity multimeter, Tool #19464 set meter to diode test position. 1.To verify that there is continuity between the inverter case and the engine frame, connect the leads of the multi-meter between the two. If continuity exists, the meter will make a continuous tone. If the meter displays OL (no continuity), a problem exists with the system wiring. Test GFCI multimeter, Tool #19464.Set meter to read resistance. 1. Disconnect output harness plug from inverter to GFCI. 2. Attach one meter test lead to small spade terminal on plug. 3. Insert other test lead into small spade terminal in GFCI receptacle. Leave lead attached through end of test Resistance should be approximately.05 ohms. 4. Rotate selector on meter to Diode Test Position 5. Place other meter lead on tractor ground. There should be no continuity. 2.To verify that there is continuity between the inverter case and the GFCI ground terminal connect the leads of the Multi meter between the two. If continuity exists, the meter will make a continuous tone. If the meter displays OL (no continuity), a problem exists with the system wiring.

Test Interlock Switch For Parking Brake If meter does not display battery voltage a problem exists with

Place equipment key switch in OFF position and lock the parking brake. 2.

Insert RED meter test lead into brake interlock switch wire connector. 4.

Meter should display battery voltage. Test POWERLINK Reset (ON-OFF) Switch multimeter, Tool #19464.

Attach a meter test lead to each terminal on switch then activate switch. 3.

4 Test Interlock Switch For Parking Brake If meter does not display battery voltage a problem exists with the equipment wiring or switch. multimeter, Tool # Set meter to DC volts. 1. Place equipment key switch in OFF position and lock the parking brake. 2. Disconnect brake interlock switch wire from red inverter wire. 3. Insert RED meter test lead into brake interlock switch wire connector. 4. Attach BLACK meter test lead to negative battery terminal. 5. Turn equipment key switch to ON position. 6. Meter should display battery voltage. Test POWERLINK Reset (ON-OFF) Switch multimeter, Tool # Set meter to DIODE TEST. 1. Remove reset (ON-OFF) switch from equipment and disconnect from harness. 2. Attach a meter test lead to each terminal on switch then activate switch. 3. With switch in ON position meter should make a continuous tone (continuity). 4. With switch in OFF position meter should display OL (no continuity). Replace switch if not to specification. Use only the POWERLINK Reset (ON-OFF) Switch recommended by the equipment manufacturer.

Check Inline Fuse Note: It may be necessary to remove the inverter from the equipment. multimeter, Tool #19464. Set meter to DIODE TEST. 1.

There must be continuity at each terminal. If the meter does not indicate continuity,the inline fuse is blown. Replace harness.

inverter. If alternator output is within specification, the inverter box is faulty and must be replaced.

5 Check Inline Fuse Note: It may be necessary to remove the inverter from the equipment. multimeter, Tool # Set meter to DIODE TEST. 1. Remove tamper proof screws from POWERLINK inverter and stator harness plugs using Torx Driver, Tool #19445 Unplug harness. 2. Check for continuity between each plug terminals as shown. 3. There must be continuity at each terminal. If the meter does not indicate continuity,the inline fuse is blown. Replace harness. Check Alternator Output If the previous tests have not revealed a faulty component, it will be necessary to check alternator output to determine whether the problem is with the alternator or the inverter. If alternator output is within specification, the inverter box is faulty and must be replaced. The Following tools are required to test alternator output: Digital multimeter; Tool #19464 POWERLINK Test Box, Tool#19528 WARNING: Make all connections before starting engine. 5. Press button on test box and note AC voltage. 6. Acceptable output is between 95 and 105VAC. 7. If output is 106 volts or higher, replace the inverter. 8. If output is 94 volts or lower, replace the stator. Remove Flywheel A special flywheel puller,tool #19534, is required when removing and installing the flywheel. WARNING:The force of the flywheel magnets is extremely high and they will rapidly draw the flywheel to the engine. Hand and/or finger injury can result. 1. Insert alternator harness plug into socket in POWERLINK test box, Tool # Set digital multimeter to read AC volts. 3. Insert meter test leads into either receptacle in test box. 4. Start engine and set speed to 1800 RPM. DO NOT EXCEED 1800 RPM. Note: It is recommended that ignition coils be removed before removing flywheel.

1. Remove flywheel nut, fan retainer and fan. 2. Install correct pilot over crankshaft. Remove Stator 1. Disconnect alternator wires from regulator-rectifier. 2. Note routing of stator wires and POWERLINK harness.

Align holes in puller flange with holes in flywheel and install puller screws. Screws must be flush with flange on puller. 5. While holding hex on puller, tighten puller screw until flywheel loosens.

Leave flywheel puller attached to flywheel and place on clean work surface with ring gear side down until flywheel is ready to be installed. Note: Use extreme care when handling flywheel.

6 1. Remove flywheel nut, fan retainer and fan. 2. Install correct pilot over crankshaft. Remove Stator 1. Disconnect alternator wires from regulator-rectifier. 2. Note routing of stator wires and POWERLINK harness. 3. Remove four screws and stator 3. Place flywheel puller over pilot and back out puller screw until flange on puller is flush with flange on flywheel. 4. Align holes in puller flange with holes in flywheel and install puller screws. Screws must be flush with flange on puller. 5. While holding hex on puller, tighten puller screw until flywheel loosens. 6. Continue tightening puller screw until flywheel is clear of stator and can be lifted from crankshaft. Leave puller screw in this position. 7. Leave flywheel puller attached to flywheel and place on clean work surface with ring gear side down until flywheel is ready to be installed. Note: Use extreme care when handling flywheel. Alternator magnets are fragile and easily damaged if flywheel is dropped or handled roughly. Note: It may be necessary to remove back plate when removing and installing stator. Install Stator 1. Route stator wires and POWERLINK harness in same position as removed and install back plate (if removed). 2. Install stator and torque screws to 25 in. lbs. (3 Nm). Install Flywheel Note: Before installing flywheel make sure flywheel magnets are free of any debris. 1. With pilot installed over crankshaft, place flywheel with puller attached over pilot. 2. Loosen puller screw slowly and lower flywheel into position over stator. 3. Reassemble fan and fan retainer to flywheel and install flywheel nut. 4. Torque flywheel nut to specification. 5. Connect alternator wires to regulator-rectifier. 6. Connect POWERLINK harness to inverter and install tamper-proof screws.

Table No. 1 provides a means of identifying the various alternator systems. Note: All output figures are rated at 3600 RPM. TABLE NO.

The alternator systems installed on Briggs & Stratton Intek OHV-Twin Cylinder Engines can easily be identified by the color of the stator output wires and the connector. Table No. 1 provides a means of