Briggs & Stratton 40451, 40450, 40449, 40481 User Manual

Not for

Reproduction

Generator Systems

Operator’s Manual

Generator System

Not for

Reproduction

Thank you for purchasing this quality-built Briggs & Stratton® home generator. We’re pleased that you’ve placed your confidence in the Briggs & Stratton brand. When operated and maintained according to the instructions in this manual, your home generator will provide many years of dependable service.

This manual contains safety information to make you aware of the hazards and risks associated with home standby generators and how to avoid them. Because we do not necessarily know all the applications this equipment could be used for, it is important that you read and understand these instructions thoroughly before attempting to start or operate this equipment. Save these original instructions for future reference.

This home generator requires professional installation before use. Refer to the separate installation manual for full information. Your installer should 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 thousands of Briggs & Stratton authorized service dealers worldwide who provide quality service. You can also contact Technical Service by phone at 800-732-2989 between 8:00 AM and 5:00 PM CT., or click on Find a Dealer at BRIGGSandSTRATTON.COM, which provides a list of authorized dealers.

Generator and engine model and serial numbers should be recorded in the installation manual.

Briggs & Stratton Power Products Group, LLC P.O. Box 702 Milwaukee, WI 53201-0702

Not for

Reproduction

Table of Contents

Important Safety Instructions........................4

Installation ....................................7

For the Home Owner:..........................................7

For the Installing Dealer/Contractor: ..............................7

Owner Orientation ............................................7

Fuel Factors .................................................8

Generator Location............................................9

Delivery Inspection...........................................10

Controls ..................................... 11

Access Ports ...............................................13

System Control Panel.........................................15

Operation .................................... 19

Engine Oil..................................................19

Battery ....................................................19

15 Amp Fuse ...............................................19

Automatic Operation Sequence .................................19

Setting Exercise Timer ........................................20

Maintenance .................................. 21

Servicing the System .........................................21

Service Code Detection System .................................21

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Generator Maintenance .......................... 23

Engine Maintenance............................. 24

Adjust Valve Lash............................................24

Engine Oil..................................................25

Service Air Cleaner...........................................26

Fuel System Inspection and Maintenance .........................27

Exhaust System Maintenance and Inspection ......................27

Service Spark Plugs..........................................27

Clean Air Cooling System and Oil Cooler Fins . . . . . . . . . . . . . . . . . . . . . . 27

When Calling for Assistance ...................................27

Storage....................................................27

Troubleshooting................................ 28

Warranty..................................... 29

Limited Warranty ............................................30

About Your Warranty .........................................31

Generator Specifications.......................... 33

Engine Specifications ............................ 33

Not for

Reproduction

Save These Instructions

Important Safety Instructions

SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.

Safety Symbols and Meanings

Explosion

Toxic Fumes

Lift Hazard

Fire

Rotating Parts

Read Manual

Electrical Shock

Hot Surface

Chemical BurnExplosive PressureAuto Start

WARNING Running engine gives off carbon monoxide,

an odorless, colorless, poison gas. Breathing carbon monoxide could result in death, serious injury, headache, fatigue, dizziness, vomiting, confusion, seizures, nausea or fainting.

• Operate this product ONLY outdoors in an area that will not accumulate deadly exhaust gas.

• Keep exhaust gas away from any windows, doors, ventilation intakes, soffit vents, crawl spaces, open garage doors or other openings that can allow exhaust gas to enter inside or be drawn into a potentially occupied building or structure.

• Carbon monoxide detector(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/recommendations. Smoke alarms cannot detect carbon monoxide gas.

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 Certain components in this product and

related accessories contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling.

The safety alert symbol indicates a potential personal injury hazard. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to designate a degree or level of hazard seriousness. A safety symbol may be used to represent the type of hazard. The signal word NOTICE is used to address practices not related to personal injury.

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, could result in minor or moderate injury.

NOTICE addresses practices not related to personal injury. 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 system unsafe.

WARNING Storage batteries give off explosive

hydrogen gas during recharging. Slightest spark will ignite hydrogen and cause explosion, resulting in death or serious injury.

Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery contents will cause severe chemical burns. A battery presents a risk of electrical shock and high short circuit current.

• DO NOT dispose of battery in a fire. Recycle battery.

• 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, rubber boots and rubber gloves.

• Remove watches, rings, or other metal objects.

• Use tools having insulated handles.

Not for

Reproduction

WARNING Generator produces hazardous voltage.

Failure to properly ground generator could result in electrocution. Failure to isolate generator from utility power could result in death or serious injury to electric utility workers due to backfeed of electrical energy.

• When using generator for backup power, notify utility company.

• DO NOT touch bare wires or bare 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.

• If you must work around a unit while it is operating, stand on an insulated dry surface to reduce the risk of a shock hazard.

• DO NOT allow unqualified persons or children to operate or service generator.

• 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.

• 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.

• Before performing any maintenance on the generator, disconnect the battery cable indicated by a NEGATIVE, NEG or (-) first. When finished, reconnect that cable last.

• After your system is installed, the generator may crank and start without warning any time there is a power failure. To prevent possible injury, always set the generator’s system switch to OFF, remove the service disconnect from the disconnect box AND remove the 15 Amp fuse BEFORE working on the equipment.

WARNING Propane and Natural Gas are extremely

flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• DO NOT operate the equipment if the “fuel shut-off” valve is missing or inoperative.

• Install the fuel supply system according to NFPA 37 and other applicable fuel-gas codes.

• Before placing the generator into service, the fuel system lines must be properly purged and leak tested.

• After the generator is installed, you should inspect the fuel system periodically.

• NO leakage is permitted.

• DO NOT operate engine if smell of fuel is present or other explosive conditions exist.

• DO NOT smoke around the generator. Wipe up any oil spills immediately. Ensure that no combustible materials are left in the generator compartment. Keep the area near the generator clean and free of debris.

WARNING Starter and other rotating parts can

entangle hands, hair, clothing, or accessories resulting in serious injury.

• NEVER operate generator without protective housings, covers, or guards in place.

• DO NOT wear loose clothing, jewelry or anything that may be caught in the starter or other rotating parts.

• Tie up long hair and remove jewelry.

• Before servicing, remove 15 Amp fuse from control panel and disconnect Negative (NEG or -) battery cable.

WARNING Unintentional sparking could cause fire or electric

shock resulting in death or serious injury.

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.

Not for

Reproduction

WARNING

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Exhaust outlet side of weatherproof enclosure must have at least 5 ft. (1.5 m) minimum clearance from any structure, shrubs, trees or any kind of vegetation.

• Standby generator weatherproof enclosure must be at least 5 ft. (1.5 m) from windows, doors, any wall opening, shrubs or vegetation over 12 inches (30.5 cm) in height.

• Standby generator weatherproof enclosure must have a minimum of 5 ft. (1.5 m) overhead clearance from any structure, overhang or trees.

• DO NOT place weatherproof enclosure under a deck or other type of structure that may confine airflow.

• Use only flexible fuel line provided. Connect provided fuel line to generator, DO NOT use with or substitute any other flexible fuel line.

• Smoke detector(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/ recommendations. Carbon monoxide alarms cannot detect smoke.

• Keep at least minimum distances shown in General Location Guidelines to insure for proper generator cooling and maintenance clearances.

• It is a violation of California Public Resource Code, Section 4442, to use or operate the engine on any forestcovered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws. Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine.

• Replacement parts must be the same and installed in the same position as the original parts.

CAUTION Installing the 15 Amp fuse could cause

Exhaust heat/gases could ignite combustibles or structures resulting in death or serious injury. Contact with muffler area could cause burns resulting in serious injury.

the engine to start at any time without warning resulting in minor or moderate injury.

CAUTION Excessively high operating speeds could

result in minor injury. Excessively low speeds impose a heavy load on generator.

• 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.

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

• Use generator only for intended uses.

• If you have questions about intended use, contact your authorized dealer.

• Operate generator only on level surfaces.

• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation.

• The Oil Fill, Oil Drain and the Control Panel doors must be installed whenever the unit is running.

• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• 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 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:

-unit makes unusual noises.

• Observe that the 15 Amp fuse has been removed from the control panel for shipping.

• DO NOT install this fuse until all plumbing and wiring has been completed and inspected.

Not for

Reproduction

Installation

We sincerely appreciate your patronage. For this reason, we have made every effort to provide for a safe, streamlined and cost-effective installation. Because each installation is unique, it is impossible to know of and advise the trade of all conceivable procedures and methods by which installation might be achieved. Neither could we know of possible hazards and/or the results of each method or procedure. For these reasons,

Only current licensed electrical and plumbing professionals should attempt home generator system installations. Installations must strictly comply with all applicable codes, industry standards and regulations.

Your home generator is supplied with this “Operator’s Manual” and a separate “Installation Manual”. These are important documents and should be retained by the owner after the installation has been completed.

This product is only for use as an optional generator system which provides an alternate source of electric power and to serve loads such as heating, refrigeration systems, and communication systems that, when stopped during any power outage, could cause discomfort or inconvenience.

NOTICE This product does NOT qualify for either an emergency standby or legally required standby system as defined by NFPA 70 (NEC).

• Emergency generator systems are intended to automatically supply illumination, power, or both, to designated areas and equipment in the event of failure of the normal supply. Emergency systems may also provide power for such functions as ventilation where essential to maintain life, where current interruption of the normal supply would produce serious life safety or health hazards.

• Legally Required standby generator systems are intended to automatically supply power to selected loads in the event of failure of the normal source which could create hazards or hamper rescue or firefighting operations.

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.

For the Home Owner:

To help you make informed choices and communicate effectively with your installation contractor(s), read and

understand Owner Orientation in this manual before contracting or starting your generator installation.

To arrange for proper installation, contact the store at which you purchased your generator, your dealer, a licensed electrician or your utility power provider.

The generator warranty is VOID unless the system is installed by licensed electrical and plumbing professionals.

The Emission Control System for this generator is warranted for standards set by the U.S. Environmental Protection Agency and by the California Air Resources Board (CARB).

For the Installing Dealer/Contractor:

For most applications, the installation manual contains all the information required to properly install and start the generator. This operator’s manual describes routine operation and owner maintenanceprocedures.

If you need more information in this matter, please call at 800-732-2989 between 8:00 AM and 5:00 PM CT.

Owner Orientation

This section provides generator owners with the information necessary to achieve the most satisfactory and cost effective installation possible.

The illustrations are for typical circumstances and are meant to familiarize you with the installation options available with your generator. A thorough understanding of these options will provide fundamental control over the cost of your installation, as well as ensure your final satisfaction and security.

Federal and local codes, appearance, noise levels, fuel types, and distances are the factors that must be considered when negotiating with an installation professional. Remember that as the distance from the existing electrical service and gaseous fuel supply increases, and the number of 90 degree bends in the fuel supply increases, compensations in piping and wiring materials must be made. This is necessary to comply with local codes and overcome electrical voltage drops and gaseous fuel pressure drops.

The factors mentioned above will have a direct affect on the overall price of your generator installation.

In some areas you may need to acquire electrical permits for installing the generator, building permits for installing gas lines, and permits for noise allowances. Your installer should check your local codes AND obtain the permits before installing the system.

Not for

Reproduction

Fuel Factors

WARNING Propane and Natural Gas are extremely

flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• The residential generator is equipped with an automatic safety gas “fuel shut-off” valve.

• DO NOT operate the equipment if the “fuel shut-off” valve is missing or inoperative.

An important consideration affecting the entire installation is the type of fuel used by your generator. The system was factory tested and adjusted using either natural gas or liquid propane (LP vapor). For proper engine function, factors that are inherent to each of these fuels, your location and the duration of possible utility interruptions are important considerations in the following fuel guidelines:

• Use clean, dry fuel, free of moisture or any particulate material. Using fuels outside the following recommended values may cause performance problems.

• In engines set up to run on propane (LP), commercial grade HD5 propane with a minimum fuel energy of 2500 BTUs/ft3 with maximum propylene content of 5% and butane and heavier gas content of 2.5% and minimum propane content of 90%.

Natural gas rating will depend on specific fuel but typical derates are between 10 to 20% off the LP gas rating.

Natural gas or LP engines are certified to operate on natural or liquid propane gas. The emissions control system for this engine is EM (Engine Modifications).

Power Decrease at High Altitude or High Temperature

Air density is less at high altitudes, resulting in less available engine power. Specifically, engine power will decrease 3.5% for each 1,000 feet (300 meters) above sea level and 1% for each 10° F (5.6°C) above 77°F (25°C). Make sure you and your installer consider these factors when determining total generator load.

Not for

Reproduction

Generator Location

The actual physical location of your generator has a direct affect on:

1. The amount of plumbing required to fuel your generator.

2. The amount of wiring required to control and connect your generator.

Specific location guidelines are discussed in the installation manual. Acquaint yourself with that information and confer with your installer. Be sure to ask how your site might affect installation costs and compliance with local codes andstandards.

• Install generator outdoors in an area that will not accumulate deadly exhaust gas.

• DO NOT install generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building or structure.

• By law it is required in many states to have a Carbon Monoxide (CO) detector in operating condition in your home. Carbon monoxide detector(s) (A) MUST be installed and maintained indoors according to the manufacturer’s instructions/recommendations. A CO monitor is an electronic device that detects hazardous levels of CO. When there is a buildup of CO, the monitor will alert the occupants by flashing visual indicator light and alarm. Smoke alarms cannot detect CO gas.

WARNING Running engine gives off carbon monoxide,

an odorless, colorless, poison gas. Breathing carbon monoxide could result in death, serious injury, headache, fatigue, dizziness, vomiting, confusion, seizures, nausea or fainting.

• Operate this product ONLY outdoors in an area that will not accumulate deadly exhaust gas.

• Carbon monoxide detector(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/recommendations. Smoke alarms cannot detect carbon monoxide gas.

WARNING Exhaust heat/gases could ignite

combustibles or structures resulting in death or serious injury.

• Exhaust outlet side of weatherproof enclosure must have at least 5 ft. (1.5 m) minimum clearance from any structure, shrubs, trees, or any kind of vegetation.

• Standby generator weatherproof enclosure must be at least 5 ft. (1.5 m) from windows, doors, any wall opening, shrubs or vegetation over 12 in. (30.5 cm) in height.

• Standby generator weatherproof enclosure must have a minimum of 5 ft. (1.5 m) overhead clearance from any structure, overhang or trees.

• DO NOT place weatherproof enclosure under a deck or other type of structure that may confine airflow.

• USE ONLY flexible fuel line provided. Connect provided fuel line to generator. DO NOT use with or substitute any other flexible fuel line.

• Smoke detector(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/ recommendations. Carbon monoxide alarms cannot detect smoke.

• DO NOT place weatherproof enclosure in manner other than shown in illustrations.

• Ensure exhaust gas is kept away from any windows, doors, ventilation intakes, soffit vents, crawl spaces, open garage doors or other openings that can allow exhaust gas to enter inside or be drawn into a potentially occupied building or structure. Your neighbor’s home may be exposed to the engine exhaust from your standby generator and must be considered when installing your standby generator.

• Wind and air currents should be taken into consideration when positioning generator.

See the installation manual for full details on safe generator location.

Not for

Reproduction

Delivery Inspection

Carefully inspect the generator for any damage that may have occurred during shipment.

If loss or damage is noted at time of delivery, have the person(s) making delivery note all damage on the freight bill and affix his signature under the consignor’s memo of loss or damage. If loss or damage is noted after delivery, separate the damaged materials and contact the carrier and your installer for claim procedures. Missing or damaged parts are not warranted.

The home generator system is supplied with:

• Oil (5W30 Synthetic)

• Flexible steel fuel line

• Installation and start-up manual

• Operator’s manual

• Spare access keys

• Spare 15 Amp ATO-type fuse

Not included:

• Carbon monoxide detector(s)

• Smoke detector(s)

• Starting battery

• Connecting wire and conduit

• Fuel supply valves/plumbing

• Crane, lifting straps, chains or cables

• Two 60” lengths of 3/4” nominal minimum scheduled 40 steel pipe (NOT conduit)

• Torque screwdriver, 5 to 50 inch-pound range

• Voltage/frequency meter

• Remote wireless monitor (OPTIONAL)

• Antenna (OPTIONAL)

Not for

Reproduction

Controls

8kW Generator

Read this Operator’s Manual and Important Safety Instructions 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.

Generator is shown with roof and access covers removed for clarity.

(A) - Lifting Holes — Provided at each corner for

lifting generator.

(B) - Exhaust Port — High-performance muffler lowers

engine noise to comply with most residential codes.

alternating current.

(D) - Spark Plug — A device in the cylinder head of the

engine that ignites the fuel mixture by means of an electric spark.

(E) - Air Cleaner — Uses a dry type filter element and foam

precleaner to protect engine by filtering dust and debris out of intake air.

(F) - Control Panel — Used for various test, operation and

maintenance functions. See System Control Panel.

(G) - Circuit Breaker — Protects the system from shorts and

other over-current conditions.

(H) - Battery (installer supplied) — 12 Volt DC, top-post

automotive style battery provides power to start the engine.

(J) - Fuel Inlet Port — Attach appropriate fuel supply to

generator here.

+ 23 hidden pages