Briggs & Stratton 40248 User Manual
7KW DUAL-MODE BACKUP GENERATOR
Operator’s Manual
Manual del Operario
Manuel d’utilisation
SAVE THESE INSTRUCTIONS
Manual No. 200267GS
Revision A (06/26/2006)
Model / Modelo/ Modèle
040248
Failure to read and follow the operator’s
manual and all operating instructions can
result in death, bodily injury, and/or
property damage.
WARNING
L’omission de lire et de suivre le manuel de
l’utilisateur et toutes les directives d’utilisation
pourrait entraîner la mort, des blessures
corporelles ou des dommages matériels.
AVERTISSEMENT
Si no se leen y siguen las indicaciones del
Manual del operario y todas las instrucciones
de uso, se pueden producir daños materiales,
lesiones o incluso la muerte.
ADVERTENCIA
Home Generator Systems
Briggs & Stratton Power Products Group, LLC
900 North Parkway
Jefferson, WI 53549
Copyright © 2006 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.
Generator
Model Number 040248
Revision _______
Serial Number __________________
Engine
Model Number _______________________________
Serial Number _______________________________
Date Purchased
Thank you for purchasing this quality-built Briggs & Stratton generator. We are pleased that you’ve placed your
confidence in the Briggs & Stratton brand. When operated and maintained according to the instructions in this manual,
your Briggs & Stratton generator will provide many years of dependable service.
This manual contains safety information to make you aware of the hazards and risks associated with gaseous fueled
generators and how to avoid them. Because Briggs & Stratton does not necessarily know all the applications this
generator could be used for, it is important that you read and understand these instructions. Keep this manual near the
generator for convenient reference.
This generator requires final assembly before use. Refer to the Assembly section of this manual for instructions on final
assembly procedures. Follow the instructions completely.
Where to Find Us
You never have to look far to find Briggs & Stratton support and service for your generator. Consult your Yellow Pages.
There are over 30,000 Briggs & Stratton authorized service dealers worldwide who provide quality service. You can also
contact Briggs & Stratton Customer Service by phone at 1-800-743-4115 or on the Internet at
www.briggsandstratton.com.
1
Table of Contents
Safety Rules.................................................................2
Equipment Description..............................................................................4
The Gaseous Fuel System.........................................................................5
Assembly/Installation .................................................6
Generator Location....................................................................................6
Attach LP Fuel Tank Housing Pad Parts................................................7
LP Fuel Tank Installation ...........................................................................8
Leak Testing Fuel System..........................................................................9
Battery Connection..................................................................................10
Generator Controls and Features...........................11
Control Panel ............................................................................................12
Receptacles ................................................................................................13
Operating Your Generator......................................14
Starting the Engine....................................................................................14
Connecting Electrical Loads...................................................................14
Stopping the Engine..................................................................................14
Don’t Overload Generator....................................................................16
Maintenance Schedule .............................................17
Oil ................................................................................................................18
Service Air Cleaner Elements................................................................19
Service Spark Plug.....................................................................................20
Check Valve Clearance ...........................................................................20
Engine Air Cooling System.....................................................................20
Charge Battery..........................................................................................20
Storage ........................................................................................................21
Troubleshooting........................................................22
Product Specifications..............................................23
Warranties ................................................................24
2
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SAVE THESE INSTRUCTIONS
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 manufacturer cannot possibly anticipate every
possible circumstance that might involve a hazard. The
warnings in this manual, and the tags and decals affixed to
the unit are, therefore, not all-inclusive. If you use a
procedure, work method or operating technique that the
manufacturer does not specifically recommend, you must
satisfy yourself that it is safe for you and others. You must
also make sure that the procedure, work method or
operating technique that you choose does not render the
generator unsafe.
Hazard Symbols and Meanings
• Operate generator ONLY outdoors.
• 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).
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide can cause nausea,
fainting 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.
WARNING
Fire
Read
Manual
Explosive
Pressure
Chemical
Burns
Explosion
Toxic Fumes
Hot Surface
Electrical Shock
• DO NOT dispose of battery in a fire.
• DO NOT allow any open flame, spark, heat, or lit cigarette during
and for several minutes after charging a battery.
• DO NOT open or mutilate the battery.
• Wear protective goggles, rubber apron, and rubber gloves.
• Remove watches, rings, or other metal objects.
• Use tools with insulated handles.
Storage batteries give off explosive hydrogen
gas during recharging.
Slightest spark will ignite hydrogen and cause
explosion.
Battery electrolyte fluid contains acid and is
extremely acidic.
Contact with battery contents will cause severe
chemical burns.
A battery presents a risk of electrical shock and
high short circuit current.
DANGER
Using a generator indoors WILL KILL YOU
IN MINUTES.
Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.
NEVER use in the home
or in partly enclosed
areas such as garages.
ONLY use outdoors and
far from open windows,
doors, and vents.
3
• 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 5100-1C or 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.
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 LP fuel tank causing a fire.
WARNING
• When using generator for backup power, notify utility company.
Use approved transfer equipment to isolate generator from
electric utility.
• DO NOT use when under the influence of drugs or alcohol.
• Despite the safe design of the generator, operating this equipment
imprudently, neglecting its maintenance or being careless can
cause possible injury or death.
• Remain alert at all times while working on this equipment. Never
work on the equipment when you are physically or mentally
fatigued.
• DO NOT touch bare wires or receptacles.
• DO NOT use generator with electrical cords which are worn,
frayed, bare or otherwise damaged.
• 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.
• If you must work around a unit while it is operating, stand on an
insulated dry surface to reduce shock hazard.
• In case of an accident caused by electrical shock, immediately shut
down the source of electrical power and contact the local
authorities. Avoid direct contact with the victim.
• Before performing any maintenance on the generator, disconnect
the battery cable indicated by a NEGATIVE, NEG or (-) first.
When finished, reconnect that cable last.
• Remove the 15 Amp fuse BEFORE working on the equipment.
When finished, replace the 15 Amp fuse.
Generator produces hazardous voltage.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
WARNING
• Generator installation must comply with all applicable codes. To
check your local codes, see your local LP gas dealer or natural gas
company.
• Properly secure fuel tanks to LP fuel tank mounting tray as
described in “Assembly”.
• Before using the generator, fuel system hoses must be properly
purged and leak tested, especially after changing fuel tanks.
• No fuel leakage is permitted. NEVER check for leaks using a match
or open flame. Strong odors, colds, sinus congestion, etc. may
prevent the detection of gaseous fuel. Use caution and common
sense when testing for leaks (see “Leak Testing Fuel System”).
• After the generator is positioned for operation, inspect the fuel
system and connecting hoses for evidence of damage, excess wear
or deterioration periodically. If such defects are found, replace
components with manufacturer-supplied replacement parts ONLY.
The fuel hoses and regulator should be replaced every five years.
• When generator is not in use, manually close fuel shut off valve(s).
• DO NOT operate generator if smell of fuel is present.
• DO NOT smoke around generator. Wipe up any oil spills
immediately. Ensure that no combustible materials are left in the
generator compartment. Keep area near the generator clean and
free of debris.
• DO NOT supply unregulated gaseous fuel to generator. See
Product Specifications for required supply pressure.
• DO NOT allow fuel hose(s) to come in contact with hot surfaces.
• DO NOT store LP gas tank(s):
Indoors or in the vicinity of the generator
In a building, garage or any other enclosed area
Within the reach of children.
• LP gas tank must have:
A safety relief device having direct communication with the
cylinder vapor space
A listed over-filling prevention device (OPD)
DOT or CAN/CSA-B339 approval
A shut off valve, terminating in a fuel outlet compatible with
a Type 1 tank connector. No other tank connectors are
permitted for use with this generator.
A collar to protect the fuel shut off valve
• DO NOT insert any foreign objects into the tank valve outlet or
any of the fuel system components.
• LP tank supply system must be arranged for vapor withdrawal.
• Have LP gas tank filled to no more than 80% capacity by a
reputable propane gas dealer and visually inspected and
re-qualified at each filling.
• ALWAYS keep LP gas tanks in an upright position.
• ALWAYS handle LP gas tanks with care.
• The LP fuel tank is equipped with an internal thermal device that
will permanently shut off gas flow if the tank is subjected to
temperatures above 240° F (115° C). If this should happen, take
the LP fuel tank to your fuel supplier. The cause of the excessive
heat should be determined and corrected before using your
generator again.
• The normal flow of gas through the regulator and hose assembly
can create a humming noise. A low volume of noise is normal and
will not interfere with generator operation. If humming noise is
loud and excessive, the fuel supply system must be purged.
Propane and Natural Gas 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 death or serious injury and/or property
damage.
WARNING
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Equipment Description
Read this manual carefully and become
familiar with your generator. Know its
applications, its limitations and any hazards
involved.
The 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 a singlecylinder engine. The generator is operated on liquefied
propane (LP) gas. It can operate on natural gas (NG) fuel
only after conversion by a licensed professional gaseous
fuel technician.
This generator incorporates GFCI (Ground Fault Circuit
Interrupter) outlet protection and has its neutral bonded
to grounding fastener to comply to OSHA inspections on
job sites.
This generator will not function when connected to a
2 pole transfer switch since its service disconnect also has
a neutral bonded to ground. When both the generator
and the home or building’s service disconnect contains a
neutral bonded to ground, the generator’s GFCI will open
and no outlets will function.
A switching neutral transfer switch MUST be used if the
generator is connected to a building’s electrical system.
This product is intended for residential use as an allweather temporary source of electric power. It is capable
of supplying power to loads such as heating, refrigeration
systems, and communication systems. This product does
not qualify for emergency standby as defined by NFPA 70
(NEC). DO NOT use this generator for anything other
than it’s intended purpose.
Every effort has been made to ensure that the information
in this manual is both accurate and current. However, the
manufacturer reserves the right to change, alter or
otherwise improve the generator and this documentation
at any time without prior notice.
• DO NOT remove the neutral bond.
• Removing the neutral bond could result in death, bodily injury
and/or property damage.
GFCI will not function if neutral bond removed
DANGER
• 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.
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
Briggs and Stratton.
• Operate generator only on level surfaces.
• Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation.
• The access door and roof must be installed whenever the unit is
running.
• DO NOT expose generator to excessive moisture, dust, dirt, or
corrosive vapors.
• DO NOT start engine with air cleaner or air cleaner cover
removed.
• DO NOT insert any objects through cooling slots.
• DO NOT use the generator or any of its parts as a step. Stepping
on the unit can cause stress and break parts. This may result in
dangerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc..
• 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
• FOR RESIDENTIAL USE ONLY. DO NOT use this generator for
anything other than its intended purpose.
• 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
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.
Unintentional sparking can result in fire or
electric shock.
WARNING
5
Ground Fault Protection
The generator’s receptacles are equipped with Ground
Fault Circuit Interrupter (GFCI) protection. This GFCI
device meets applicable federal, state and local codes.
The GFCI protects against electrical shock that may be
caused if your body becomes a path in which electricity
travels to reach the ground. This could happen if you
touch a “Live” appliance or wire, or are touching plumbing
or other materials that connect to the ground.
When protected by a GFCI device, one may still feel a
shock, but the GFCI should cut current off quickly enough
so that a person in normal health should not suffer any
serious electrical injury.
Connections
to a Building’s Electrical
System
Connections from this generator to a building’s electrical
system must be made through a switching neutral transfer
switch installed by a qualified electrician. The connection
must isolate the generator power from utility power, and
must comply with all applicable laws and electrical codes.
IMPORTANT: A switching neutral transfer switch MUST
be used when switching between utility and generator power.
Customer’s Responsibilities
• If considering installation with a transfer swith, read
and follow the instructions given in this manual.
• Follow a regular schedule in maintaining, caring for
and using your generator, as specified in this manual.
• ALWAYS disconnect and store indoors the cord used
to connect generator and inlet connection box when
generator is not in use.
To help you make informed choices and communicate
effectively with your installation contractor(s),
Read and understand the Assembly section of
this manual before starting your generator
installation.
You can arrange for proper installation by contacting the
store at which you purchased your generator, your Briggs
& Stratton dealer, a licensed professional electrician or
your utility power provider.
The generator warranty is VOID if permanent fuel
connections to the generator are installed by
anyone other than a licensed gaseous fuel
professional.
The generator warranty is VOID if permanent
electrical connections to the generator are made.
The Gaseous Fuel System
The generator unit has been factory set to run on
liquefied petroleum gas. If the generator is to run on
natural gas, the engine will need to be reconfigured using
the supplied NG Conversion kit. Contact a licensed
professional gaseous fuel technician to install this kit.
The generator engine is fitted with a fuel mixer system
that meets the specifications of the California Air
Resources Board for “tamper-proof” dual fuel systems.
The unit will run on natural gas or liquefied propane
vapor.
• Use clean, dry fuel, free of moisture or any particulate
material. Using fuels outside the following
recommended values may cause performance
problems:
• Commercial grade HD5 LPG is recommended minimum fuel energy of 2500 BTU’s/ft
3
with maximum
propylene content of 5% and butane and heavier gas
content of 2.5% and minimum propane content of 90%.
• See “Specifications” for required fuel supply pressure.
Fuel Consumption
See the following table for fuel supply requirements at half
and full load for both natural gas and LP vapor.
• Contact with the hot and neutral conductor at the same time can
cause electrical shock or burn, even if the circuit is GFCI
protected.
• Before using the GFCI receptacle, ALWAYS push the test button
to insure it works.
Generator produces hazardous voltage/current.
WARNING
Only qualified electricians and gaseous fuel
technicians should attempt fuel conversion or
permanent connection of this generator. Each
installation must strictly comply with applicable
codes, standards and regulations.
WARNING
• LP gas is heavier than air and will settle in low areas.
• Natural gas is lighter than air and will collect in high areas.
• The slightest spark can ignite these fuels and cause an explosion.
• IF YOU SMELL GAS - Shut off gas to the generator at the LP
cylinder(s)/source.
• If odor continues, leave the area and immediately call your gas
supplier or fire department.
Propane and Natural Gas are extremely
flammable and explosive.
Fire or explosion can cause severe burns or
death.
WARNING
Natural Gas* LP Vapor**
1/2 Load Full Load 1/2 Load Full Load
80 137 33 56
* = Natural Gas is in cubic feet per hour
** = LP Vapor is in cubic feet per hour
Fuel Supply Requirements
Generator Location
Consider these factors when determining the proper
generator operating location:
• Install the unit outdoors on a flat, level surface with
provisions for adequate ventilation. This will allow for
dispersion of deadly exhaust gas. DO NOT install
generator where exhaust gas could accumulate and
enter inside or be drawn into a potentially occupied
building areas.
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 1). Prevailing winds and air currents should be
taken into consideration when positioning generator.
• The unit must have at least 5 ft. (152 cm) of clearance
on all sides of the enclosure and LP tank housing pad,
including overhead. This will reduce the risk of
exhaust heat or exhaust gases igniting nearby
combustible materials and will provide for adequate
cooling and generator maintenance.
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Assembly/Installation
Your generator is ready for use after you assemble the LP
fuel tank housing pad components, make proper fuel
connections, and verify that engine oil is at the proper
level.
If you have any problems with the assembly of your
generator, please 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. See “Generator Controls and Features” for data
tag location.
Shipment Contents
The generator is supplied with:
• Generator pre-attached to mounting pad
• LP fuel tank housing tray assembly pre-attached to
mounting pad
• Fuel hose and regulator assembly pre-attached to
generator
• LP fuel tank all-weather cover
• Bag containing LP fuel tank attachment hardware
• Operator’s manual
• Battery
• Oil drain tray
• Touch-up paint
• One spare 15A fuse
• NG conversion kit
You must purchase two filled 20 pound DOT LP fuel tanks
that are equipped with a listed over-filling prevention
device (OPD).
Lifting the Generator
CAUTION The generator weighs more than
280 pounds (130 kg). Proper tools, equipment and
qualified personnel should be used in all phases of
handling and moving the generator. Each full LP
tank will weigh more than 20 pounds (9 kg).
CAUTION DO NOT lift unit by roof as damage to
generator will occur.
Lifting pockets are provided at each corner between the
base of the generator and its mounting pad. See
“Generator Controls and Features” for locations. Retouch
any chipped paint with supplied touch-up paint.
• Keep at least 5 ft. (152 cm) clearance on all sides of generator
including overhead.
Exhaust heat/gases can ignite combustibles,
structures or damage LP fuel tank causing a fire.
WARNING
CAUTION
• Refer to Maintenance for oil fill information.
• Damage to equipment resulting from failure to follow this
instruction will void warranty.
Any attempt to crank or start the engine without
verifying it has been properly serviced with the
recommended oil will result in equipment failure.
Figure 1 — Generator Clearances
A - Engine Exhaust Opening
A
Using a generator indoors WILL KILL YOU
IN MINUTES.
Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.
NEVER use in the home
or in partly enclosed
areas such as garages.
ONLY use outdoors and
far from open windows,
doors, and vents.
7
• Install the unit in a location where sump pump
discharge, rain gutter down spouts, roof run-off,
landscape irrigation, or water sprinklers will not flood
the unit or spray the enclosure and enter any air inlet
or outlet openings.
• Install the unit where the location of any services such
as phone, electrical, fuel, air conditioning, irrigation,
including covered, concealed and underground
services will not be affected or obstructed.
• Install the unit where air inlet and outlet openings will
not become obstructed by leaves, grass, snow, etc. If
prevailing winds will cause blowing or drifting, you
may need to construct a windbreak to protect the
unit.
The generator is shipped already attached to its mounting
pad. Unless mandated by local code, a concrete slab is not
required.
If mandated by local code, construct a concrete slab at
least 3 inches thick and 6 inches longer and wider than the
combined generator and LP tank pad footprint. Attach
pads to slab with 1/4” diameter (minimum) masonry
anchor bolts.
Attach LP Fuel Tank Housing Pad Parts
Required Tools
You will need either of the following tools to attach the
LP fuel tank housing pad to the generator pad:
• 1/2 inch (13 mm) socket and ratchet OR
• 1/2 inch (13 mm) open end wrench
Attach Mounting Pads Together
1. Place LP tank housing pad (with pre-attached LP fuel
tank tray) on the ground next to the side of the
generator where the fuel hose(s) and regulator are
attached.
Confirm that the pre-drilled holes on both mounting
pads are adjacent to each other (see Figure 2).
2. Lay one 20 inch (50 cm) angle bracket across both
mounting pads, aligning the bracket holes with the
pre-drilled pad holes, as shown in Figure 2.
3, Pass one 5/16” X 1” lag bolt through one 5/16” flat
washer, then through one hole on the angle bracket.
Finger tighten lag bolt into mounting pad hole (see
Figure 3).
4. Repeat Step 3 three more times, placing a lag
bolt/washer in each angle bracket hole.
5. Tighten each lag bolt until snug using specified tool.
DO NOT over-tighten as threads could strip.
6. Repeat Steps 2 through 5 to attach the second angle
bracket to the opposite ends of the mounting pads.
Attach Tank Hold-Down Rod
Insert either end of the supplied threaded rod into the LP
fuel tank tray location shown in Figure 4. Hand tighten
rod.
Figure 2 — Mounting Pad and Angle Bracket Holes
A - Mounting Pad Holes
B - Angle Bracket
B
A
Figure 3 — Start Lag Bolts into Mounting Pad Holes
A - Mounting Pad
B - Flat Washer
C - Lag Bolt
D - Angle Bracket
C
DBA
Figure 4 — Attach Tank Hold-Down Rod to LP Tank Tray
A - Hold-Down Rod
B - LP Fuel Tank Tray
A
B
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