Briggs & Stratton 01933-1 User Manual

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Operator’s Manual

Manuel d’utilisation

Manual del Operario

Model / Modèle / Modelo

PRO6500

01933-1

Questions? Help is just a moment away! Call: Generator Helpline

Vous avez des questions? Vous n'avez pas besoin d'aller loin pour trouver de l'aide! Appelez: Ligne d'assistance de Générateur

Preguntas? La ayuda es justa un momento lejos! Llame: Línea Directa del Generador 1-800-743-4115 M-F8-5CT

BRIGGSandSTRATTON.COM

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

Manual No. 195994GS

Revision E (02/13/2007)

BSPP Generator

SAVE THESE INSTRUCTIONS

TABLE OF CONTENTS

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

EQUIPMENT DESCRIPTION

Read this manual carefully and become familiar with your generator. Know its applications, its limitations and any hazards involved.

This generator is an engine–driven,revolving field, alternating current (AC) generator. It was designed to 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 the engine.

This generator incorporates GFCI (Ground Fault Circuit Interrupter) outlet protection and has its neutral bonded to ground to comply to OSHA inspections on job sites.

This generator will not function when connected to a 2 pole transfer switch since the home or building main breaker box also has a neutral bonded to ground.When

both the generator and the home or building breaker box contains a neutral bonded to ground, the generators GFCI will open and no outlets will function.

WARNING

DO NOT remove the neutral bond.

Removing the neutral bond could result in death, bodily injury and/or property damage.

CAUTION! DO NOT exceed the generator’s wattage / amperage capacity. See “Don’t Overload Generator”.

Every effort has been made to ensure that information in this manual is accurate and current. However, we reserve 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 and the California Air Resources Board. For warranty information refer to the engine operator’s manual.

SAFETY RULES

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

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 indicates a hazard which, if not avoided,might result in minor or moderate injury.CAUTION, when usedwithout the alert symbol, indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Hazard Symbols and Meanings

Operator’s Manual Toxic Fumes

Electrical Shock

Kickback

Explosion

Fire

Hot Surface Explosive Pressure

Chemical Burn

Copyright © 2007 Briggs & Stratton Power Products Group, LLC. All rights reserved. No part of this material may be reproduced or transmitted in any form by any means without the express written permission of Briggs & Stratton Power Products Group, LLC.

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BSPP Generator

DANGER

Storage batteries give off explosive hydrogen gas during recharging.

Hydrogen gas stays near battery for a long time after battery has been charged.

Slightest spark will ignite hydrogen and cause explosion.

You can be blinded or severely injured.

Battery electrolyte fluid contains acid and is extremely caustic.

Contact with battery fluid will cause severe chemical burns.

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.

WARNING

Running generator gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause nausea, fainting or death.

Operate generator 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.

DO NOT operate generator inside any building or enclosure (even if doors or windows are open), including the generator compartment of a recreational vehicle (RV).

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WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WHEN ADDING OR DRAINING FUEL

Turn generator OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

Fill or drain fuel 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.

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 tip engine or equipment at angle which causes fuel to spill.

This generator is not for use in mobile equipment or marine applications.

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF.

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 can ignite fuel vapors.

WARNING

This generator does not meet U. S. Coast Guard Regulation 33CFR-183and 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.

BSPP Generator

WARNING

Generator produces powerful voltage.

Failure to isolate generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy.

When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility.

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 receptacles.

DO NOT use generator with electrical cords which are worn, frayed, bare or otherwise damaged.

DO NOT operate generator in the rain or wet weather.

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

Unintentional sparking can result in fire or electric shock.

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR GENERATOR

Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact spark plug.

WHEN TESTING FOR ENGINE SPARK

Use approved spark plug tester.

DO NOT check for spark with spark plug removed.

WARNING

Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150°F (65°C).

Severe burns can occur on contact.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

DO NOT touch hot surfaces and avoid hot exhaust gases.

Allow equipment to cool before touching.

Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead.

Code of Federal Regulation (CFR) Title 36 Parks, Forests, and Public Property require equipment powered by an internal combustion engine to have a spark arrester, maintained in effective working order, complying to USDA Forest service standard 5100-1Cor later revision. In the State of California a spark arrester is required under section 4442 of the California Public resources code. Other states may have similar laws.

WARNING

Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises or sprains could result.

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.

CAUTION

Excessively high operating speeds increase risk of injury and damage to generator.

Excessively low speeds impose a heavy load.

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

Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.

See “Don’t Overload Generator”.

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.

CAUTION

Improper treatment of generator can damage it and shorten its life.

Use generator only for intended uses.

If you have questions about intended use, ask dealer or call 1-800-743-4115.

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 generator.

Shut off generator if:

-electricaloutput is lost;

-equipmentsparks, smokes, or emits flames;-unitvibrates excessively.

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BSPP Generator

KNOW YOUR GENERATOR

Read this Operator’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. Save this manual for future reference.

Oil Fill Cap

Fuel Tank

Circuit Breakers

Hour Meter

 

12 Volt DC

 

Receptacle

 

Idle Control Switch

 

120 Volt AC, 20 Amp

 

Duplex Receptacle

 

120 Volt AC, 30 Amp

 

Locking Receptacle

 

120/240 Volt AC, 30 Amp

Grounding

Locking Receptacle

Fastener

12 Volt DC Receptacle — Use this receptacle with battery charge cables to charge a 12 Volt battery.

120Volt AC, 20 Amp Duplex Receptacle — 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.

120Volt AC, 30 Amp Locking Receptacle — May be used to supply electrical power for the operation of 120Volt AC, 30 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle — May be used to supply electrical 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 — Protects engine by filtering dust and debris out of intake air.

Choke Lever — Used when starting a cold engine.

Circuit Breakers (AC) — Push to reset circuit breakers are provided to protect the generator against electrical overload.

Choke Lever

Air Cleaner

Data Tag

Spark Arrester Muffler

GFCI Circuit Breaker

Data Tag – Provides model, revision and serial number of generator. Please have these readily available if calling for assistance.

Fuel Tank — Capacity of seven (7) U.S. gallons.

GFCI Circuit Breaker — A GFCI circuit breaker is provided to protect against electrical ground fault and protect the generator against electrical overload.

Grounding Fastener — Consult your local agency having jurisdiction for grounding requirements in your area.

Hour Meter — Displays and records how many hours your generator has run (up to 9,999.9).

Idle Control Switch — The idle control runs the engine at normal (high) speeds when there is a load present and runs the engine at idle (low) speeds when a load is not present.

Oil Fill Cap — Add oil to engine here.

Spark Arrester Muffler — Exhaust muffler lowers engine noise and is equipped with a spark arrester screen.

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BSPP Generator

 

 

 

 

ASSEMBLY

Engine operator’s manual

 

 

 

 

(2) Locking 30A plugs

Your generator requires some assembly and is ready for

Battery charge cables

use after it has been properly serviced with the

Engine oil

recommended oil and fuel.

Wheel kit

If you have any problems with the assembly of your

 

 

generator, please call the generator helpline at 1-800-743-4115.

Unpacking the Generator

1.Set the carton on a rigid flat surface.

2.Remove everything from carton except generator.

3.Open carton completely by cutting each corner from top to bottom.

4.Leave generator on carton to install wheel kit.

Install Wheel Kit

NOTE: Wheel kit is not intended forover-the-roaduse. You will need the following tools to install these components:

7/16” and 13mm wrench

Socket wrench with a 13mm and a 7/16” socket

Pliers

Safety glasses

Refer to Figure 1 and install the wheel kit as follows:

Carton Contents

Check all contents. If any parts are missing or damaged, call the generator helpline at 1–800–743–4115.

The generator

Generator operator’s manual

1.Tip generator so that engine end is up.

2.Slide axle through both mounting brackets.

3.Place a wheel on each side with air valve facing out.

4.Place a washer on axle and then place an e-ringin axle groove.

Figure 1 — Install Wheel Kit

Handle Pin

Your unit may vary slightly from that shown here

Nylon Washer

 

 

Nylon Washer

45 mm Cap Screw

 

Flat Washer

Wheel

Nut

Handle

Flat Washer

Use existing hardware Nut

Axle

 

20 mm Cap Screw

 

to attach left side of

 

support leg to unit

 

E-Ring

Vibration Mount

Support Leg

 

 

 

3/4” Cap Screw

Nut

 

6

BSPP Generator

5.Install e-ringwith pliers, squeezing from top ofe-ringto bottom of axle.

CAUTION

E-ringscan cause eye injury.

E-ringscan spring back and become airborne when installing or removing.

• Always wear eye protection when installing/removing e-rings.

6.Repeat step 3 through 5 to secure second wheel.

7.Attach vibration mounts to support leg with 1/4-20x 1” capscrews and1/4-20lock nuts.

8.Tip generator so that engine side is down.

9.Remove existing hardware from left unit vibration mount with 13mm wrench. Use same hardware to attach support leg.

10.Attach other side of support leg with a M8 x 20 mm capscrew and M8 lock nut.

11.Attach handles to handle brackets on generator frame, as shown in Figure 1, with M8 x 45 mm capscrews, flat washers, nylon washers, and M8 lock nuts.

NOTE: Be sure to install the nylon washers between the handle brackets on the generator frame and the brackets on the handle assembly.

12.Return generator to normal operating position (resting on wheels and support leg).

NOTE: Check oil often during enginebreak–in.Refer to engine operator’s manual for recommendations.

NOTE: The alternator assembly rotates on a prelubricated and sealed ball bearing that requires no additional lubrication for the life of the bearing.

Add Fuel

NOTE: This gasoline engine is certified to operate on gasoline. Exhaust Emission Control System: EM (Engine Modifications).

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WHEN ADDING FUEL

• Turn generator OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

Fill fuel 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.

DO NOT light a cigarette or smoke.

13.Loop handle pins to generator frame as shown in Figure 1. Raise handles and insert handle pins to move generator.

14.Check each fastener to ensure it is secure and the tires are inflated between 15-40PSI.

BEFORE STARTING THE ENGINE

Add Engine Oil

Place generator on a level surface.

Refer to engine operator’s manual and follow oil recommendations and instructions.

CAUTION

Any attempt to crank or start the engine before it has been properly filled with the recommended oil will result in equipment failure.

Refer to engine operator’s manual for oil fill information.

Damage to equipment resulting from failure to follow this instruction will void warranty.

1.Use clean, fresh, regular UNLEADED fuel with a minimum of 87 octane with equipment. DO NOT use fuel which contains Methanol. DO NOT mix oil with fuel.

2.Clean area around fuel fill cap, remove cap.

3.Slowly add regular unleaded fuel to fuel tank. Be careful not to fill above the baffle.This allows adequate space for fuel expansion (Figure 2).

Figure 2 — Typical Fuel Expansion Space

TANK

Baffle

FUEL

4.Install fuel cap and let any spilled fuel evaporate before starting engine.

7

BSPP Generator

USING THE GENERATOR

System Ground

The generator has a system ground that connects the generator frame components to the ground terminals on the AC output receptacles.The system ground is connected to the AC neutral wire (see “Equipment Description”, earlier in this manual).

Special Requirements

There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction.

In some areas, generators are required to be registered with local utility companies.

If the generator is used at a construction site, there may be additional regulations which must be observed.

Connecting to a Building’s Electrical System

Connections for standby power to a building’s electrical system must be made by a qualified electrician.The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes.

NOTE: Neutral must be transfered when switching between utility and generator power.

WARNING

Generator produces powerful voltage.

Failure to isolate generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy.

When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility.

DO NOT touch bare wires or receptacles.

DO NOT use generator with electrical cords which are worn, frayed, bare 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.

Generator Location

Generator Clearance

WARNING

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead.

Place generator in a well ventilated area, which will allow for removal of deadly exhaust gas. DO NOT place generator where exhaust gas 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 (Figure 3). Prevailing winds and air currents should be taken into consideration when positioning generator.

Figure 3 — Generator Clearance

Typical Generator Shown

Exhaust Port

8

BSPP Generator

OPERATING THE

GENERATOR

Starting the Engine

Disconnect all electrical loads from the generator. Use the following start instruction steps in numerical order:

1.Make sure unit is on a level surface.

IMPORTANT: Failure to start and operate unit on a level surface will cause the unit not to start or shut down during operation.

2.Turn fuel valve to “On” position (Figure 4).

Figure 4 — Fuel Shut-offValve

3.Make sure Idle Control switch is in “Off” position (Figure 5).

Figure 5 — Idle Control Switch

4.Follow start instructions given in engine operator’s manual.

WARNING

Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150°F (65°C).

Severe burns can occur on contact.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

DO NOT touch hot surfaces and avoid hot exhaust gases.

Allow equipment to cool before touching.

Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead.

Code of Federal Regulation (CFR) Title 36 Parks, Forests, and Public Property require equipment powered by an internal combustion engine to have a spark arrester, maintained in effective working order, complying to USDA Forest service standard 5100-1Cor later revision. In the State of California a spark arrester is required under section 4442 of the California Public resources code. Other states may have similar laws.

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, single phase, 60 Hz electrical loads.

DO NOT connect 240 Volt loads to the 120 Volt duplex receptacles.

DO NOT connect 3–phaseloads to the generator.

DO NOT connect 50 Hz loads to the generator.

DO NOT OVERLOAD THE GENERATOR. See “Don’t Overload Generator”.

WARNING

Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises or sprains could result.

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.

NOTE: If engine starts after 3 pulls but fails to run, or if unit shuts down during operation, make sure unit is on a level surface and check for proper oil level in crankcase.

This unit may be equipped with a low oil protection device. See engine operator’s manual.

CAUTION

Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.

See “Don’t Overload Generator”.

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.

9

BSPP Generator

Stopping the Engine

1.Turn OFF and unplugALL electrical loads from generator panel receptacles. NEVER start or stop engine with electrical devices plugged in and turnedON.

2.Move idle control switch to “Off” position.

3.Let engine run at no-loadfor several minutes to stabilize internal temperatures of engine and generator.

4.Move fuel valve to “Off” position.

5.Turn engine off according to instructions given in the engine operator’s manual.

Operating Automatic Idle Control

This switch is designed to greatly improve fuel economy.

When this switch is turned ON, the engine will only run at its normal high governed engine speed when electrical loads are connected.When an electrical load is removed, the engine will run at a reduced speed.

With the switch off, the engine will run at the normal high engine speed.Always have the switch off when starting and stopping the engine.

Charging a Battery

Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage battery.

• DO NOT use the unit to charge any 6 Volt batteries.

DO NOT use the unit to crank an engine having a discharged battery.

To recharge 12 Volt batteries, proceed as follows:

1.Check fluid level in all battery cells. If necessary, add ONLY distilled water to cover separators in battery cells. DO NOT use tap water.

2.If battery is equipped with vent caps, make sure they are installed and are tight.

3.If necessary, clean battery terminals.

4.Connect battery charge cable connector plug to panel receptacle identified by the words “12-VOLTSD.C.”.

5.Move idle control switch to “Off” position.

6.Connect battery charge cable clamp with red handle to thepositive (+) battery terminal (Figure 6).

Figure 6 — Battery Connections

7.Connect battery charge cable clamp with black handle to thenegative (–) battery terminal (Figure 6).

8.Start engine. Let engine run while battery recharges.

DANGER

Storage batteries give off explosive hydrogen gas during recharging.

Hydrogen gas stays near battery for a long time after battery has been charged.

Slightest spark will ignite hydrogen and cause explosion.

You can be blinded or severely injured.

Battery electrolyte fluid contains acid and is extremely caustic.

Contact with battery fluid will cause severe chemical burns.

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.

9.When battery has charged, shut down engine

NOTE: Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturer’s instructions carefully. Generally, a battery is considered to be at 100% state of charge when specific gravity of its fluid (as measured by hydrometer) is 1.260 or higher.

10