Briggs & Stratton Generator User manual

Briggs& StrattonPower ProductsHome Generator STstem
Owners Manual
TABLE OF CONTENTS
Safety Rules .................................. 2-3
Assembly .................................... 4-5
Know Your Generator ........................... 6
Operation ................................... 7-9
Product Specifications/Maintenance ............... 10
Storage...................................... I I
Troubleshooting ............................... 12
Notes ....................................... 13
Schematic/Wiring Diagram ................... 14-15
Replacement Parts........................... 16-19
Warranty ............................... Last Page
EQUIPMENT
DESCRIPTION
Read this manual carefully and become familiar
with your generator. Know its applications, its
limitations and any hazards involved.
This generator isan engine-driven, revolving field,alternating
current (AC) generator. It was designedto supply electrical
power for operating compatible electrical lighting,appliances,
tools and motor loads.The generator's revolving field is
driven at about 3,600 rpm by asingle-cylinder engine.
CAUTION! Do Not exceed the generator's
wattage/amperage capacity.See "Don't Overload the
Generator" on page 9.
Every effort hasbeen made to ensure that informadon in this
manual is accurate and current. However, Briggsand Stratton
reserves the right to change,alter or otherwise improve the
product and this document at any time without prior notice.
The Emission Control System for this generator is warranted
for standards set by the Environmental Protection Agency. For
warranty information refer to the engine owner's manual.
WARNING 1
The engine exhaust from this product contains I
chemicals known to the State of California to cause|
cancer, birth defects, or other reproductive harm.
SAFETY RULES
The safety alert symbol (_) is used with a signal word
(DANGER, CAUTION.WARNING), a pictorial and/or a
safety message to alert you to hazards. 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
indicatesa hazard which, if not avoided,might result in
minor or moderate injury. CAUTION, when used
without the alert symbol, indicatesa situation that could
result in equipment damage.Follow safety messagesto
avoid or reduce the risk of injury or death.
DANGER
Operate generator ONLY outdoors.
Keep at least 2 feet of deea'ance on all sidesof generator for
adaquate ventilation.
Do not operategeneratorinsideanybuildingor enclosure,
includingthe generator €ompartmentof arecreational vehicle
(RV).
WARNING
WHEN ADDING FUEL
Turn generator OFF and let it cool at least 2minutes before
removing gas cap.Loosen cap tiow_ to relieve pressure in tank.
Fill fuel tank outdoors.
Do not overfill tank.Allow space for fuel expansion.
Keep gasoline away from sparks, open flarnes,pilot lights, heat,
and other ignition sources,
Do not light a cigarette or smoke.
VHEM OPERATING EQUIPMENT
•Do not tip engine or equipment at angle which causes
gasoline to spill.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT
•Transport/repair with fuet tank EMPTY or with fuel shutoff
•valve OFE
Disconnect spark plugwire.
WHEN STORING GASOLINE 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 can ignite gasoline vapors.
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Briggs& StrattonPowerProductsHome GeneratorS)'stem
Owners Manual
c_e_ _,J GdiwH_w
WARNING
When usinggenerator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.
Use a ground fault circuit interrupter (GFCI) in any damp or
highly conductive area, such as me4:aldecking or steel work.
Do not touch bare wires or receptacles.
Do not use generator with electrical cords which are worn,
frayed, hare or otherwise damaged.
Do not operate generator in the rain.
Do not handle generator or electrical cords while standing in
water, while barefoot, or while hands or feet are wet.
Do not allow unqualified persons or children to operate or
service generator.
WARNING
Do not touch hot surfaces.
Allow equipment to cool before touching.
CAUTION
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.
CAUTION
See "Don't OverloadYour Generator" on page 9.
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.
DANGER
Do not allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.
Wear protective goggles, rubber apron, and rubber gloves.
CAUTION
Use generator only for intended uses.
If you have questions about intended use,ask dealer or
contact Briggs and Stratton.
Operate generator only on level surfaces.
Do not expose generator to excessive moisture, dust, dirt, or
corrosive vapors.
Do not insert any objects through cooling slots.
If connected devices overheat, turn them off and disconnect
them from generato_
Shut off generator ih
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.
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Bri_s & Stratton Power Products Home Generator System
Owners Manual
Your generator requires some assemblyand is ready for
use after it hasbeen properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the generator helpline at
1-800-746-4115.
IMPORTANT: Anyattemptto run the unitbeforeit has
beenservicedwith the recommendedoilwill result inan
enginefailure.
REMOVE GENERATOR
FROM CARTON
• Set the carton on a rigid flat surface with "This Side Up"
arrows pointing upward.
• Carefully open the top flapsof the shipping carton.
• Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.
• Remove all packing material, carton fillers, etc.
•Remove the generator from the shipping carton.
Carton Contents
Check all contents. If any parts are missing or damaged, call
the home standby helpline at 1-800-746-4115.
•5500 watt generator
• Manual transfer switch
Wheel kit
Locking30 Amp plug
Engineoil
Owner's manual
Enginemanual
Warranty sheet
Installation checklist
INSTALL WHEEL KIT
The wheel kit is designed to greatly improve the portability
of your generator.
NOTE:Wheel kit is not intended for over-the-road use.
You will need a socket wrench with 1/2" or 13mm sockets
and a needle-nose pliers to install this kit
Refer to Figure Iand install the wheel kit as
follows:
I. Place the generator on a hard fiat surface,
2. Stand at the engine end of the generator and gently tilt
the generator forward, high enough to place wooden
blocks beneath the cradle.This will allow you to add
the wheels.
3. Slide the axle through the holes in the brackets
provided on the generator cradle.
4. Slide a wheel and flat washer on one end of the axle.
Make sure the air inflation valve is outward. Insert the
retaining pin.
Cap Screw
Hex Nut -
Handle Assembly
Use existing hardware
to attach left side of Hex Nut
support leg to unit
Vibration
Cap Screw
Cap Screw
-HexNut
Wheel
FlatWasher
/
Retaining Pin
/4

Briggs&Stratton Power Products Home Generator System
Owners Manual
5. Slide the axle through until wheel istight against
bracket
6,
7.
8.
9.
Slide the other wheel and flat washer on the other end
of the axle. Make sure the air inflation valve isoutward.
Insert the retaining pin using the needle-nose plier.
Remove the wooden blocks.
Attach the vibration mounts to the support leg with
30mm capscrews,washers and lock nuts.
To aid support leg assembly, rest generator on cradle,
engine end down. Remove the existing hardware from
the left unit vibration mount with 13ram wrench. Use
the same hardware to attach the support leg.
Attach the other side of the support leg with a 20mm
cap screw and lock nut Rest generator on wheels and
support leg.
I0. Center the handle bracket on generator frame at
support leg end of cradle, as shown.
I I. Attach handlebracket with two M8 x 45ram cap
screws andtwo locking hex nuts.
12. Check each fastener to ensure it is secure and the
tires are inflated between 15-40 PSI.
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! Any attempt to crank or start the engine
before it hasbeen properly filled with the recommended
oil may result in an engine failure.
To fill your engine with oil:
• Place generator on a levelsurface.
•Follow the oil grade recommendations and oil fill
instructions given in the engine owner's manual.
NOTE: The generator's revolving field rides on a
prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing,
Add Gasoline
_K ARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine isrunning or hotAllow unit
to cool for two minutes before refueling. Do Not
lighta cigarette or smoke when fillingthe fuel tank.
_WARNING! Do Not overfillthe fuel tank
Alwaysallowroom for fuel expansion.
•Use regular UNLEADED gasolinewith the generator
engine. Do Not use premium gasoline.Do Not mix oil
with gasoline.
• Clean area around fuel fill cap,remove cap.
• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill.Allow about 1.5"of tank space for
fuel expansion (Figure 2).
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essentialfuel system parts,such as the
carburetor, fuel filter, fuel hose or tank during storage.Also,
experience indicates that alcohol_lended fuels (called
gasohol, ethanol or methanol) can attract moisture, which
leads to separation and formation of acids during storage.
Acidic fuel can damage the fuel system of an engine while in
storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See "Storage"
on page I I. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
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Bri_s&StrattonPower Products Home Generator System
Owners Manual
KNOWYOUR GENERATOR
Read this owner's manual and safety rules before operating your generator.
Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and
adjustments. Savethis manual for future reference.
Recoil Starter Rocker Switch
(on engine shroud)
Oil Fill
FuelTank
Air Cleaner
120Volt AC, 20 Amp
Duplex Receptacles
Circuit 120/240 Volt AC,
Breakers (AC) 30 Amp
Receptacle
120Volt AC, 20 Amp, Duplex Receptacles -- May be
used to supply electrical power for the operation of
120Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting,
appliance,tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle -- May
be used to supplyelectrical power for the operation of
120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical, lighting,appliance, tool and motor loads.
Air Cleaner -- Uses adry type filter element to limit the
amount of dirt and dust sucked into the engine.
Choke Lever -- Used when starting a cold engine.
Spark Arrester Muffler
GroundingWing Nut
Circuit Breakers (AC) -- Push to reset circuit breakers
are provided to protect the generator against electrical
overload.
Fuel Tank -- Capacity of seven (7) U.S.gallons.
GroundingWing Nut -- Used for proper grounding of
unit.
Oil Fill--Add engine oi! here.
Recoil starter -- Used to start the engine.
Rocker Switch -- Set this switch to "On" before using
recoil starter. Set switch to "Off' to switch off engine.
Spark Arrester Muffler -- Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.
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Briggs& Stratton Power Products Home Generator S)'stem
Owners Manual
GROUNDING THE
GENERATOR
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 3).
Wing Nut
I. Turn the fuel valve to the "On" position (Figure 4).
FuelValve is shown
in the On position
2. Placethe choke lever in the "Choke" position
(Figure 5).
Generally, connecting aNo. 12AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection againstelectrical
shock. Be careful to keep the grounding wire attached after
connectingthe stranded copper wire. However, local codes
may vary widely.Consult with a local electrician for
grounding requirements in your area.
Properly groundingthe generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipatestatic electricity, which often builds up in
ungrounded devices.
OPERATING THE
GENERATOR
,_ CAUTION! Never start or stop the engine with
electrical loads connected to the receptacles AND
with the connected devices turned ON.
Starting the Engine
Disconnect all electrical loads from the generator. Use the
following start instruction steps by numerical order:
3. Set the rocker switch to "On" position (Figure 6).
4.
5.
Grasp the recoil handle and pull slowly until slight
resistance is felt.Then pull rapidly to start engine.
Move choke lever to "Run" position a short distance at
a time over several seconds in warm weather or
minutes in cold weathe_ Let engine run smoothly before
each change. Operate with choke in"Run" position.
NOTE: If engine still fails to start after 3pulls, check for
proper oil level in crankcase.This unit is equipped with a
low oil device which prevents the engine from being
started when the oil drops below a safe level in the
crankcase. See engine manual.
Refer to the engine owner's manual for more
detailed starting instructions.
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Briggs& Stratton Power Products Home Generator System
Owners Manual
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 Volt AC,
singlephase, 60 Hz electrical loads.
•Do Not connect 240Volt loadsto the 120Volt duplex
receptacles.
•Do Not connect 3-phase loadsto the generator.
• Do Not connect 50 Hz loadsto the generator.
•DO NOT OVERLOADTHE GENERATOR. See
"Don't Overload the Generator" on page 9.
Stopping the Engine
•Unplug all electrical loadsfrom generator panel
receptacles. Never start or stop engine with electrical
devices pluggedin and turned ON.
• Let engine run at no-load for several minutes to stabilize
the internal temperatures of engine and generator.
• Move rocker switch to"Off" position.
• Move the fuel valve to the"Off' position.
RECEPTACLES
120/240 Volt AC, 30 Amp, Locking
Receptacle
Use aNEMA LI4-30 plug with this receptacle. Connect a
4-wire cord set rated for 250Volt AC loads at 30Amps (or
greater) (Figure 7).You can use the same 4-wire cord if you
plan to run a 120Volt load.
This receptacle powers 120/240Volt AC, 60 Hz, single
phase loads requiring up to 5,500 watts of power (5.5 kW)
at 30Amps for 120Volts or 240Volts.The oudet is
protected by a push-to-reset circuit breaker.
_CAUTION! Although this outlet states it has a
120/240 Volt 30 Amp rating (up to 7,200 watts), the
generator is only rated for 5,500 watts. Powering
loads that exceed the wattage/amperage capacity of
the generator can damage it or cause serious
injuries.
4-Wire Cord Set
(Neutral)
Y (Hot) | X (Hot)
/
NEMA L 14-30 _ Ground (Green)
120 Volt AC, 20 Amp, Duplex
Receptacles
Eachduplex receptacle (Figure 8) is protected against
overload by a push-to-reset circuit breaker.
Use each receptacle to operate 120Volt AC, single-phase,
60 Hz eJectrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125Volt AC loads at 20 Amps (or greater).
_CAUTION.IThese outlets are rated at 120Volt
20 Amp each (up to 80 Amps),The generator is only
rated for up to 45.8 Amps. Powering loads that
exceed the wattage/amperage capacity of the
generator can damage it or cause serious injuries,
w8

Bri_s & Stratton Power Products Home Generator System
Owners Manual
DON'T OVERLOADYOUR
GENERATOR
Capacity
You must make sure your generator can supplyenough
rated (running) and surge (starting) watts for the items you
will power at the same time. Follow these simple steps:
I. Select the items you will power at the same Ume.
2. Total the rated (running) watts of these items.This is
the amount of power your generator must produce to
keep your items running.See Figure 9.
3. Estimate how many surge (starting) watts you will
need.Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliancessuchasa circular saw or refrigerator.
Becausenot all motors start at the same time, total
surgewatts can be estimated by adding only the
item(s) with the highestadditional surge watts to the
total rated watts from step 2.
Example:
TooJ or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Total Rated (Runninl
Rated (Running)
Watts
1200
8O0
500
500
75
3075 Total
RunningWatts
Watts =3075
HighestAdditional SurgeWatts = 1800
Total Generator Output Required =4875
Additional Surge
(Starting)Watts
1800
1600
500
1800Highest
SurgeWatts
Power Management
To prolong the life of your generator and attached devices,
it is important to take care when adding electrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it's engine.The correct
and safe way to manage generator power is to sequentially
add loadsas follows:
I. With nothing connected to the generator, start the
engine as described in this manual.
2. Plug in and turn on the first load, preferably the largest
load you have.
3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.
4. Plug in and turn on the next load.
5. Again, permit the generator to stabilize.
6. Repeat steps4 and 5 for each additional load.
Never add more loads than the generator capacity.Take
special care to consider surge loads in generator capacity,
as described above.
Tool or Appliance
Essentials
Light Bulb - 75 watt
Deep Freezer
Sump Pump
Refrigerator/Freezer ° 18 Cu. Ft.
Water Well Pump -I/3 HP
Heating/Cooling
Window AC - 10,000 BTU
Window Fan
Furnace Fan Blower- I/2 HP
Kitchen
Microwave Oven -1000 Watt
Coffee Maker
Electric Stove -Single Element
Hot Plate
Family Room
DVD/CD Player
VCR
Stereo Receiver
Color Television -27"
Personal Computer w/17" monitor
Other
Security System
AM/FM Clock Radio
Garage Door Opener- I/2 HP
Electric Water Heater -40 Gallon
DIYIJob Site
Quartz Halogen Work Light
Airless Sprayer - 1/3 HP
Reciprocating Saw
Electric Drill - I/2 HP
Circular Saw - 7 I/4"
Miter Saw - 10"
Table Planer - 6"
Table Saw/Radial Arm Saw -10"
Air Compressor - P-I/2 HP
Rated*
(Running)
Watts
7S
5O0
8OO
8OO
1000
Additional
Surge
(Starting)
Watts
500
1200
1600
2000
1200 1800
300 600
800 1300
1000
IS00
1500
2500
I00
I00
450
5OO
800
180
30O
480 520
4000
1000
600 1200
960 960
1000 1000
IS00 1500
1800 1800
1800 1800
2000 2000
2500 2500
*Wattages listed are approximate only, Check tool or
appliance for actual wattage.
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Brig;_s& Stratton Power Products Home Generator System
Owners Manual
SPECIFICATIONS
Maximum SurgeWatts ................. 8,500 watts
Continuous Wattage Capacity ........... 5,500 watts
Power Factor .............................. 1.0
Rated Maximum Continuous AC Load Currant:
At 120Volts ...................... .45.8 Amps
At 240Volts ....................... 22.9 Amps
Phase ................................. I-phase
Rated Frequency ....................... 60 Hertz
FuelTank Capacity ................... 7U.S.gallons
ShippingWeight ......................... 197 Ibs.
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on atimely
basis;that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator.
Engine Maintenance
See engine owner's manual for instructions.
If you need service for your engine, you need to determine
the engine identification number.To do so,remove the
rocker arm cover hood, item number 55 shown on
page 16,by removing the four nuts and washers holding it
in place.The engine model-type-trim number is stamped on
the side of the inner cover attached to the engine.Have
this number in hand when you call the engine service
center for assistance.
Generator Maintenance
Generator maintenance consistsof keeping the unit clean
and dry, Operate and store the unit in a clean dry
environment where it will not be exposed to excessive
dust.dirt, moisture or any corrosive vapors.Cooling air
slotsin the generator must not become cloggedwith snow.
leavesor any other foreign material.
NOTE: Do Not use a garden hose to clean generator.
Water can enter enginefuel systemand cause problems. In
addition, if water enters generator through cooling air slots,
some of the water will be retained in voids and cracks of
the rotor and stator winding insulation.Water and dirt
buildup on the generator internal windings will eventually
decrease the insulation resistance of these windings.
To Clean the Generator
_k AUTION! Never insert any object or tool
through the air cooling slots,even if the engine is
not running.
• Use a damp cloth to wipe exterior surfaces clean.
• A soft brisde brush may be used to loosen caked on dirt
or oil.
•A vacuum cleaner may be used to pick up loose dirt and
debris.
•Low pressure air (not to exceed 25 psi) may be usedto
blow away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.
ACAUTION! 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. DONq"
POLLUTE. CONSERVE RESOURCES. RETURN
USED OILTO COLLECTION CENTERS.
10