Briggs & Stratton 01532-2 User Manual

Owner’s Manual

Manuel de l'utilisateur

Manual del Propietario

Model 01532-2

Manual No. 192115GS

Revision 0 (01/07/2003)

Questions? Help is just a moment away!

Vous avez des questions? Vous n'avez pas besoin d'aller loin pour trouver de l'aide!

Preguntas? La ayuda es justa un momento lejos!

Call: Generator Helpline - 1-800-743-4115 M-F 8-5 CT

Appelez: Ligne d'assistance de Générateur - 1-800-743-4115 M-F 8-5 CT

Llamada: Generador Helpline - 1-800-743-4115 M-F 8-5 CT

1000

Starting

Watts

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON, WISCONSIN, U.S.A.

900W Generator

TABLE OF CONTENTS

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

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Schematic/Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 17

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 18-25

Emmision Control Warranty . . . . . . . . . . . . . . . . . . . . . 26

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

EQUIPMENT

DESCRIPTION

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

The generators are 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 a single-cylinder engine.

CAUTION! DO NOT exceed the generator’s

wattage/amperage capacity. See “Don’t Overload the Generator” on page 10.

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.

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 used without 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.

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

WARNING

In the State of California a spark arrester is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. If you equip the muffler with a spark arrester, it must be maintained in effective working order.

900W Generator

• 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.

Storage batteries give off explosive hydrogen gas during recharging.

Hydrogen gas stays around 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.

DANGER

WHEN ADDING FUEL

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

• Fill fuel tank outdoors.

• DO NOT overfill tank. Allow space for fuel expansion.

• Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.

• DO NOT light a cigarette or smoke.

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.

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WARNING

• This generator does not meet U. S. Coast Guard Regulation 33CFR-183 and should not be used on marine applications.

• Failure to use the appropriate U. S. Coast Guard approved generator could result in bodily injury and/or property damage.

WARNING

• Operate generator ONLY outdoors.

• Keep at least 2 feet of clearance on all sides of generator for adequate ventilation.

• DO NOT operate generator inside any building or enclosure, including the generator compartment of a recreational vehicle (RV).

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

Breathing carbon monoxide will cause nausea, fainting or death.

DANGER

• National Electric Code requires generator to be properly grounded to an approved earth ground. Call an electrician for local grounding requirements.

Failure to properly ground generator can result in electrocution, especially if the generator is equipped with a wheel kit.

DANGER

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

• Use a ground circuit fault 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.

• 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 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.

DANGER

900W Generator

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

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

Severe burns can occur on contact.

WARNING

• 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.

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

Excessively low speeds impose a heavy load.

CAUTION

• See “Don’t Overload Your Generator” on page 10.

• 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.

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

CAUTION

• Use generator only for intended uses.

• If you have questions about intended use, ask dealer or contact your nearest authorized service center.

• 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:

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

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

CAUTION

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.

Unintentional sparking can result in fire or electric shock.

WARNING

900W Generator

12 Volt DC, 8.3 Amp Accessory Jack — May be used

to power 12 Volt DC electrical devices or recharge 12 Volt DC batteries.

120 Volt AC, 7.5 Amp Receptacles — May be used to supply electrical power for the operation of 120 Volt AC, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

Air Cleaner — Uses a foam element to limit the amount of dirt and dust that enters the engine.

Choke Lever — Used to manually provide proper starting mixture when engine is cold.

Circuit Breaker (AC) — Receptacles are provided with a push-to-reset circuit breaker to protect the generator against electrical overload.

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

Engine ON/OFF Switch — Used to stop a running engine.

Fuel Shut-Off Valve — Use this valve to turn the fuel supply on and off.

Fuel Tank — Capacity of 1.2 U.S. gallons (4.5 liters) of fuel.

Grounding Lug — Use this connection to properly ground the generator. See ”Grounding the Generator” on page 7.

Oil Fill/Drain — Access to oil fill dipstick and engine oil drain plug.

Recoil Starter — Used for starting the engine. Spark Plug — Access to engine spark plug.

KNOW YOUR 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. Save this manual for future reference.

120 Volt AC, 7.5 Amp

Receptacle

Recoil Starter

Circuit Breaker (AC)

Oil Fill/Drain

(inside cover)

Choke Lever

Spark Plug (inside

cover)

Fuel Tank

Air Cleaner

Grounding Lug

12 Volt DC, 8.3 Amp

Accessory Jack

Engine ON/OFF Switch

Fuel Shut-Off Valve

Data Tag

900W Generator

ASSEMBLY

Carton Contents

Check all contents. If any parts are missing or damaged, call the generator helpline at 1-800-743-4115. If calling for assistance, please have the model, revision, and serial number from the data tag available. Shipped with your generator is:

• Main unit

• Oil bottle

• Owner’s manual

• Battery charge cables

BEFORE STARTING ENGINE

Add Oil

NOTE: When adding oil to the engine crankcase in the

future, use only high quality detergent oil rated with API service classification SG, SF/CC, CD. Select the oil’s viscosity grade according to your expected operating temperature:

SAE 10W-30 is recommended for general all temperature use. Multi-viscosity oils (10W30, etc.) improve starting in cold weather, but these oils will result in increased oil consumption. Check your engine oil level more frequently to avoid possible damage from running low on oil.

To Add Engine Oil:

• Place the generator on a level surface.

• Remove the oil fill cover.

• Remove oil filler cap and wipe dipstick clean (Figure 1).

• If the oil level is not at the point of overflowing from the oil filler neck, slowly fill engine with recommended oil.

• Reinstall oil filler cap and tighten securely.

• Replace the oil fill cover.

• Check the engine oil level before starting each time thereafter.

Add Fuel

WARNING! NEVER fill fuel tank indoors. NEVER

fill fuel tank when engine is running or hot. Allow unit to cool for two minutes before refueling. DO NOT light a cigarette or smoke when filling the fuel tank.

WARNING! DO NOT overfill the fuel tank.

Always allow room for fuel expansion.

• Use clean fresh UNLEADED fuel with a pump rating of 86 or higher. DO NOT use premium or leaded fuel. DO NOT mix oil with fuel.

• Clean area around fuel fill cap, remove cap.

• Check the fuel level.

• If fuel level is low, slowly add recommended fuel to fuel tank, up to the shoulder of the fuel strainer (Figure 2). Be careful not to overfill (there should be no fuel in the filler neck).

NOTE: Occasionally clear the fuel strainer of any dirt, rust, or other particulate matter.

• Install fuel cap and wipe up any spilled fuel.

Occasionally you may hear a light “spark knock” or “pinging” (metallic rapping noise) while operating under heavy loads. This is no cause for concern. If spark knock or pinging occurs at a steady engine speed under normal load, change brands of fuel or obtain a higher octane rated fuel. If pinging or spark knock persists, see your local Briggs & Stratton repair center.

colder 32°F warmer

SAE 10W30 SAE 30

Oil Filler Neck

Figure 1 — Adding Engine Oil

Fill to This Level

Figure 2 — Fuel Level

900W Generator

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 housing (Figure 3).

Generally, connecting a No. 12 AWG (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 against electrical shock. Be careful to keep the grounding wire attached after connecting the stranded copper wire. However, local codes may vary widely. Consult with a local electrician for grounding requirements in your area.

Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or in connected electrical devices. Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices.

OPERATING THE

GENERATOR

CAUTION! NEVER start or stop the engine with

electrical loads connected to the unit and with the connected devices turned ON.

Starting the Engine

Disconnect all electrical loads from the generator. Use the following start instructions:

• Be sure the spark plug wire is attached to the spark plug.

• Turn the fuel valve to the “Open” position (fully

clockwise) (Figure 4).

• Slide the choke lever to the “Choke” position (all the

way to the right) (Figure 5).

• Place the engine switch in the “On” position (Figure 6).

• Grasp starter grip and slowly pull the rope until you feel some resistance, then pull the cord out with a rapid full arm stroke. Let rope return slowly. DO NOT let rope “snap back” against the unit.

Figure 5 — Choke Lever

Figure 4 — Fuel Valve in Open Position

Figure 6 — Engine Switch in On Position

Figure 3 — Grounding Wing Nut

Grounding Wing Nut

900W Generator

NOTE: If engine starts after 3 pulls, but fails to run for

more than 10 seconds, check for proper oil level in crankcase. This unit is equipped with a Oil Alert System (see page 8).

• Slide the choke lever left to the “Run” position as the

engine warms up.

NOTE: Under no load conditions, the engine speed may vary slightly faster or slower until engine temperatures stabilize.

CAUTION! Breathing Hazard! NEVER run

engine in enclosed poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after starting.

• DO NOT connect 240 Volt loads to 120 Volt receptacles.

• DO NOT connect 3–phase loads to the generator.

• DO NOT connect 50 Hz loads to the generator.

• Plug in and turn on the desired 120 Volt AC, single phase, 60 Hertz electrical loads.

• DO NOT OVERLOAD THE GENERATOR. Add up the rated watts (or amps) of all loads to be connected at one time. This total should not be greater than the rated wattage/amperage capacity of the generator. See “Don’t Overload the Generator” on page 10.

Stopping the Engine

• Unplug all electrical loads from the unit. NEVER start or stop engine with electrical devices plugged in and turned on.

• Let engine run at no–load for two minutes to stabilize the internal temperatures.

• Move engine switch to the “Off” position.

• Turn the fuel valve to the “Close” position (fully counterclockwise).

NOTE: In an emergency, stop the engine by moving the engine switch to the “Off” position.

Oil Alert System

The Oil Alert System is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert System will automatically shut down the engine (the engine switch will remain in the “On” position).

If the Oil Alert System shuts down the engine, add engine oil.

Charging a Battery

WARNING! Storage batteries emit explosive gas

while charging that remains around a battery for a long time after it has been charged. The slightest spark can ignite the gas, causing an explosion that can shatter the battery and cause blindness or other injury.

WARNING! DO NOT permit smoking, open

flame, sparks or any other source of heat around a battery. DO NOT use a lighter or other flame for checking battery fluid levels. Wear protective goggles, rubber apron and rubber gloves when working around a battery. Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. DO NOT permit fluid contact with eyes, skin, clothing, etc. If spill occurs, flush area with clear water immediately.

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:

• If necessary, clean battery posts or terminals.

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

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

• Connect battery charge cable connector plug to the 12 Volt DC panel receptacle.

• Connect battery charge cable clamp with red handle to battery post or terminal indicated by Positive, POS or (+) (Figure 7).

900W Generator

• Connect battery charge cable clamp with black handle to battery post or terminal indicated by Negative, NEG, or (–) (Figure 7).

• Start generator. Let the engine run while battery recharges.

• When battery has charged, shut down engine (see “Stopping The 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.

CONNECTOR PLUGS

120 Volt AC, 15 Amp Receptacle

Each outlet socket is protected against overload by a

7.5 Amp push-to-reset circuit breaker. Use each receptacle

to operate 120 Volt AC, single phase, 60 Hz electrical loads requiring up to 1,000 watts (1.0 kW) of power (Figure 8).

CAUTION! Although each receptacle is rated

for 120 Volts at 15 Amps (1,440 watts or 1.44 kW), the generator is rated for a total of 1,000 watts. Powering loads that exceed the wattage capacity of the generator can damage it or cause serious injuries. The total of loads powered through these receptacles should not exceed 7.5 Amps.

12 Volt DC Accessory Jack

This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cable provided. Camping-style air pumps, lanterns, fans, or other 12 Volt devices having a cigarette lighter-type plug may also be powered by this outlet (Figure 9).

This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery. See “Charging a Battery” (page 8) before attempting to recharge a battery.

EXTENSION CORDS

Use only high quality, well-insulated, extension cords with the generator’s 120 Volt electrical receptacles.

Check the ratings of all extension cords before you use them. Such cords should be rated for 125 Volt AC loads at 15 Amps (or greater) for most electrical devices. Some devices, however, may not require this type of extension cord. Check the owner’s manuals of those devices for their recommendations.

Keep extension cords as short as possible, preferably less than 15 feet long, to prevent voltage drop and possible overheating of wires.

Figure 8 — 120 Volt AC, 15 Amp Duplex Receptacle

Figure 9 — 12 Volt DC Accessory Jack

Red Lead

To 12 Volt DC Panel Receptacle

Positive

Negative

Figure 7 — Battery Connections

900W Generator

DON'T OVERLOAD YOUR

GENERATOR

Capacity

You must make sure your generator can supply enough rated (running) and surge (starting) watts for the items you will power at the same time. Follow these simple steps:

1. Select the items you will power at the same time.

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 10.

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 appliances such as a circular saw or refrigerator. Because not all motors start at the same time, total surge watts can be estimated by adding only the item(s) with the highest additional surge watts to the total rated watts from step 2.

Example:

Total Rated (Running) Watts = 3075 Highest Additional Surge Watts = 1800 Total Generator Output Required = 4875

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 loads as follows:

1. 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 steps 4 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.

*Wattages listed are approximate only. Check tool or appliance for actual wattage.

Tool or Appliance

Rated (Running)

Watts

Additional Surge

(Starting) Watts Window Air Conditioner

1200 1800

Refrigerator 800 1600 Deep Freezer 500 500 Television 500 Light (75 Watts) 75 -

3075 Total

Running Watts

1800 Highest

Surge Watts

Tool or Appliance

Rated*

(Running)

Watts

Additional

Surge

(Starting)

Watts

Essentials

Light Bulb - 75 watt

Deep Freezer

500

Sump Pump

800

1200

Refrigerator/Freezer - 18 Cu. Ft.

800

1600

Water Well Pump - 1/3 HP

1000

2000

Heating/Cooling

Window AC - 10,000 BTU

1200

1800

Window Fan

300

600

Furnace Fan Blower - 1/2 HP

800

1300

Kitchen

Microwave Oven - 1000 Watt

1000

Coffee Maker

1500

Electric Stove - Single Element

1500

Hot Plate

2500

Family Room

DVD/CD Player

100

VCR

100

Stereo Receiver

450

Color Television - 27”

500

Personal Computer w/17” monitor

800

Other

Security System

180

AM/FM Clock Radio

300

Garage Door Opener - 1/2 HP

480

520

Electric Water Heater - 40 Gallon

4000

DIY/Job Site

Quartz Halogen Work Light

1000

Airless Sprayer - 1/3 HP

600

1200

Reciprocating Saw

960

Electric Drill - 1/2 HP

1000

Circular Saw - 7 1/4”

1500

Miter Saw - 10”

1800

Table Planer - 6”

1800

Table Saw/Radial Arm Saw - 10”

2000

Air Compressor - 1-1/2 HP

2500

Figure 10 - Wattage Reference Chart

900W Generator

PRODUCT

SPECIFICATIONS

Generator Specifications

Rated Surge Watts . . . . . . . . . . . . . . . 1,000 Watts

Rated Running Watts . . . . . . . . . . . . . 900 Watts

Rated Maximum Current

At 120 Volts AC . . . . . . . . . . . . . .7.5 Amps

At 12 Volts DC . . . . . . . . . . . . . . .8.3 Amps

Phase . . . . . . . . . . . . . . . . . . . . . . . .Single Phase

Rated Frequency . . . . . . . . . . . . . . . .60 Hertz

Packaged Weight . . . . . . . . . . . . . . . .61 lbs.

Engine Specifications

Model

. . . . . . . . . . . . . . . . . . . . . . . .

Mitsubishi GM82

Rated Horsepower . . . . . . . . . . . . . . 2.4 at 4000 rpm

Displacement . . . . . . . . . . . . . . . . . . . 80cc

Spark Plug Type: . . . . . . . . . . . . . . . . . NGK BP6HS or

equivalent

Set Gap To: . . . . . . . . . . . . . . . . . . . . . 0.030inch (0.75mm)

Fuel Capacity . . . . . . . . . . . . . . . . . . . 1.2 U.S. gallons (4.5 l)

GENERAL MAINTENANCE

RECOMMENDATIONS

The generator warranty does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain generator as instructed in this manual.

Some adjustments will need to be made periodically to properly maintain your generator.

All adjustments in this section should be made at least once each season. Follow the requirements in the “Maintenance Schedule” chart shown below in Figure 11.

NOTE: Once a year you should clean or replace the spark plug and replace the air filter. A new spark plug and clean air filter assure proper fuel-air mixture and help your engine run better and last longer.

GENERATOR

MAINTENANCE

Generator maintenance consists of 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 slots in the generator must not become clogged with snow, leaves or any other foreign material.

1 Clean more often under dirty or dusty conditions. Replace cleaner parts if very dirty. 2 Check every 10 hours or 3 months. 3 These items should be serviced by an authorized dealer, unless the owner has the proper tools and is mechanically

proficient.

Item

Operation

Each use

First Month or

25 hours

Every 3 months

or 50 hours

Every 6 months

or 100 hours

Engine oil

Check level X

Change X X Air cleaner

Check X Clean

X (1)

Spark arrester

Check – Clean

X (2,3)

Spark plug

Check – Clean

Valve clearance

Check – Adjust

X (3)

Fuel tank strainer

Clean X (3) Fuel line

Check (Replace if necessary)

Every 3 years (3)

Figure 11 – Maintenance Schedule

900W Generator

Check the cleanliness of the generator frequently and clean when dust, dirt, oil, moisture or other foreign substances are visible on its exterior surface.

NOTE: DO NOT use a garden hose to clean generator. Water can enter engine fuel system and 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

• Use a damp cloth to wipe exterior surfaces clean.

• Soft, bristle brush may be used to loosen caked on dirt or oil.

CAUTION! NEVER insert any object or tool

through the air cooling slots, even if the engine is not running.

• A vacuum cleaner may be used to pick up loose dirt and debris.

• Low pressure air (not to exceed 25 psi) may be used to blow away dirt. Inspect cooling air slots and opening on generator. These openings must be kept clean and unobstructed.

WARNING! When working on the generator

always disconnect spark plug wire from spark plug and keep it away from spark plug.

ENGINE MAINTENANCE

Checking Oil Level

Oil level should be checked prior to each use or at least every 5 hours of operation. Keep oil level maintained.

Changing Engine Oil

Change the oil after the first month of operation, then every 25 hours. If you are using your generator under extremely dirty or dusty conditions, or in extremely hot weather, change the oil more often.

Change the oil while the engine is still warm from running, as follows:

• Remove the oil fill cover and clean area around oil drain plug (Figure 12).

• Remove oil drain plug, sealing washer, and oil filler cap. Drain oil completely into a suitable container.

• Install oil drain plug and sealing washer. Tighten securely.

• Refill with recommended oil and check the level. See page 6 for oil recommendations.

• Wipe up any spilled oil.

CAUTION! 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. DON'T POLLUTE. CONSERVE RESOURCES. RETURN USED OIL TO COLLECTION CENTERS.

• Replace oil fill cover.

Clean/Replace Spark Plug

Check and clean the spark plug every 50 hours of operation or every three months, whichever comes first. This will help your engine to start easier and run better.

• Remove spark plug access cover. Remove spark plug cap.

• Clean the area around the spark plug.

• Remove and inspect the spark plug.

• Replace the spark plug if electrodes are pitted or burned or the porcelain is cracked. Use recommended plug for replacement.

• Check electrode gap with wire feeler gauge and set spark plug gap between 0.028 and 0.031 inch (0.7 to 0.8 mm) if necessary (Figure 13).

Figure 12 — Oil Drain Plug

Oil Drain Plug

900W Generator

• Reinstall spark plug.

Service Air Cleaner

Your engine will not run properly and may be damaged if you run it using a dirty air filter element.

Check the air filter every use and clean or replace the paper air filter element every 50 hours of operation or every three months, whichever comes first. Clean or replace more often if operating under dusty or dirty conditions.

To clean or replace air filter element:

• Loosen the air cleaner cover screws, remove the air cleaner cover, and remove the element (see item number 4, exploded view on page 22.

• Wipe clean the inside of the filter housing and cover thoroughly.

• Wash the element in a solution of household detergent and warm water, then rinse thoroughly. Or wash in nonflammable or high flash point solvent. Allow the element to dry thoroughly.

• Soak the element in clean engine oil and squeeze out the excess oil. DO NOT twist. The engine will smoke during initial start-up if too much oil is left in the element.

NOTE: If you need to order a new air filter element, please call 1-800-743-4115.

• Reinstall the air cleaner element and the cover. Hand tighten the air cleaner cover screws.

Clean Spark Arrester Screen

The engine muffler is equipped with a removable spark arrester screen. Inspect and clean the screen every 10 hours of operation or every three months, as shown in Figure 14:

• Loosen the screw on the muffler tail pipe and remove the spark arrester screen.

• Use a brass or stiff-bristle brush to remove carbon deposits from the spark arrester surface.

• Inspect the spark arrester for breaks or tears and replace it if necessary.

NOTE: If you need to order a new spark arrester, please call 1-800-743-4115.

• Install the clean screen in the reverse order of removal.

NOTE: If you use your generator on any forest-covered, brush-covered or grass-covered unimproved land, it must have a spark arrester installed. The spark arrester must be maintained in good condition by the owner/operator.

STORAGE INSTRUCTIONS

Transporting and Storage

When transporting the generator, turn the engine switch to “Off” and the fuel valve to “Close”. Keep the generator level to prevent fuel spillage.

WARNING! Contact with a hot engine or

exhaust system can cause serious burns or fires. Let the engine cool before transporting or storing the generator. Take care to not drop or strike the generator when transporting. DO NOT place heavy objects on the generator.

The generator should be started at least once every seven days and allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than 30 days, use the following guidelines to prepare it for storage.

Figure 13 — Service Spark Plug

Spark Arrester

Screen

Muffler Tail Pipe

Spark Arrester

Attachment Screw

Figure 14 – Service Spark Arrester Screen

900W Generator

Long Term Storage Instructions

WARNING! NEVER store engine with fuel in

tank indoors or in enclosed, poorly ventilated areas where fumes may reach an open flame, spark or pilot light as on a furnace, water heater, clothes dryer or other gas appliance. Be sure the storage area is free from excessive humidity and dust.

One Month to One Year

Drain the carburetor float bowl (see following section) and fuel tank into a suitable container. After removal from storage, fill with fresh fuel before starting.

More than One Year

It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor, fuel filter, fuel hose or tank during storage. Also, experience indicates that alcohol-blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to separation and formation of acids during storage. Acidic gas 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. Follow these instructions:

Protect Fuel System

WARNING! Drain fuel into approved container

outdoors, away from open flame. Be sure engine is cool. DO NOT smoke.

• Drain carburetor float bowl and fuel tank into a suitable container by loosening the drain screw (Figure 15).

• Retighten drain screw before refueling.

Change Oil

While engine is still warm, change oil as described on page 12. Refill with recommended grade.

Oil Cylinder Bore

• Remove spark plug and pour about one tablespoon of clean engine oil into the cylinder.

CAUTION! Avoid spray from spark plug hole

when cranking engine slowly.

• Cover spark plug hole with rag. Crank slowly several times to distribute oil.

• Install spark plug. DO NOT connect spark plug wire.

• Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed. Storing the engine in this position will help to protect it from internal corrosion.

Generator

• Clean the generator as outlined on page 12 (“To Clean the Generator”).

• Check that cooling air slots and openings on generator are open and unobstructed.

Other Storage Tips

• DO NOT store fuel from one season to another.

• Replace the fuel can if it starts to rust. Rust and/or dirt in fuel will cause problems.

• If possible, store your unit indoors. BE SURE TO

EMPTY THE FUEL TANK.

• Cover your unit with a suitable protective cover that does not retain moisture.

IMPORTANT: NEVER cover your generator while engine and exhaust area are warm.

• Store generator in clean, dry area.

Carburetor Fuel

Drain Screw

Drain Screw Access Hole

Figure 15 – Drain Fuel From Carburetor

900W Generator

NOTES

900W Generator

TROUBLESHOOTING

Problem

Cause

Correction

No AC or DC output

is available but engine is running.

1. One of the circuit breakers is open.

2. Fault in generator.

3. Poor connection or defective cord set.

4. Connected device is bad.

1. Reset circuit breaker.

2. Contact Briggs & Stratton Power Products service facility.

3. Check and repair.

4. Connect another device that is in good condition.

Generator runs good

at no-load but “bogs down" when loads are connected.

1. Short circuit in a connected load.

2. Engine speed is too slow.

3. Generator is overloaded.

4. Shorted generator circuit.

1. Disconnect shorted electrical load.

2. Contact Briggs & Stratton service facility.

3. See “Don't Overload the Generator” on page 10.

4. Contact Briggs & Stratton Power Products service facility.

Engine will not start;

or starts and runs rough.

1. Engine switch set to “Off”.

2. Fuel valve in the “Closed” position.

3. Dirty air cleaner.

4. Out of gasoline.

5. Stale gasoline.

6. Spark plug wire not connected to spark plug.

7. Bad spark plug.

8. Water in gasoline.

9. Overchoked or flooded.

10. Excessively rich fuel mixture.

11. Intake valve stuck open or closed.

12. Engine has lost compression.

1. Set switch to “On”.

2. Turn fuel valve to the “Open” position.

3. Clean or replace air cleaner.

4. Fill fuel tank.

5. Drain gas tank and carburetor; fill with fresh fuel.

6. Connect wire to spark plug.

7. Replace spark plug.

8. Drain gas tank and carburetor; fill with fresh fuel.

9. Wait 5 minutes and re-crank engine.

10. Contact Briggs & Stratton service facility.

11. Contact Briggs & Stratton service facility.

12. Contact Briggs & Stratton service facility.

Engine shuts down

when running.

1. Out of gasoline.

2. Low oil level.

1. Fill fuel tank.

2. Fill cranckcase to proper level.

Engine lacks power.

1. Load is too high.

2. Dirty air filter.

1. See “Don't Overload the Generator”

on page 10.

2. Replace air filter.

Engine “hunts” or

falters.

1. Choke is opened to soon.

2. Carburetor is running too rich or too lean.

1. Move choke to halfway position until engine runs smoothly.

2. Contact Briggs & Stratton service facility.

900W Generator

WIRING DIAGRAM

900W Generator

EXPLODED VIEW AND PARTS LIST – MAIN UNIT

Item Part # Qty Description

1 NSP 1 ENG, MITSUB, 2.4HP 2 187378GS 1 ROTOR 3 187411GS 1 BRG 4 187379GS 1 STATOR 5 187430GS 1 LEAD, GREEN 6 187409GS 1 BUSHING, LEAD WIRE, G790B 7 187381GS 1 RBC, 1K 8 187399GS 3 SCREW, SELF TAP, M6-12

9 187382SGS 1 FAN, COOLING 10 187388GS 1 BOLT, RTR 11 187389GS 3 BOLT, STATOR 12 187405GS 1 INSLTN, HEAT SEALED, #1 13 187384GS 1 MFFLR, SEALED 14 187407GS 1 INSLTN, HEAT SEALED, #2 15 187403GS 1 DUCT, AIR

Item Part # Qty Description

16 187392GS 2 PHMS, M6-1.0, W/L/FW 17 187383GS 1 BASE, GEN 18 187390GS 4 BOLT, FLNG, M6-1.0 X 10 19 187385GS 4 MNT, VIBR 20 187427GS 4 HHCS, FLNG, M8-1.25 X 12 21 187424GS 1 NUT, WING, M5 X 0.8 22 187423GS 1 NUT, M5 X 0.8 23 187419GS 2 WSHR, LOCK 24 187420GS 2 WSHR, FLAT 25 187401GS 2 NUT, M8-1.25, FLANGE 26 187415GS 1 PHMS, M5-0.8 X 20 27 187413GS 2 CNNCTR 28 187434GS 4 HHCS, FLNG 29 187431GS 1 STND, ENG

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