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

Generator Systems

Operator’s Manual

Generator System

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.

Reproduction
Generator and engine model and serial numbers should be recorded in the installation manual.
Not	for

Briggs & Stratton Power Products Group, LLC

P.O. Box 702

Milwaukee, WI 53201-0702

Copyright © 2014. All rights reserved. No part of this material may be reproduced or transmitted in any form without the express

written permission of Briggs & Stratton Power Products Group, LLC.

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
Reproduction
Automatic Operation Sequence . . . . . . . . . . . . . . . . . 19
Setting Exercise Timer . . . . . . . . . .	. . . . . .			.   20
Maintenance . . . . . . . . . . . . . . . . . 21
Servicing the System . . . . . . . . . . .	. . . . .		.		21
Service Code Detection System . . . . . . .	. . . . .		. . . . 21
Adjust Valve Lash . for. . . . . . . . . . .	. . . . .		24
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Generator Maintenance . . . . . . .	. . . .			.	.	23
Not	. . . .			.	.	24
Engine Maintenance . . . . . . . .
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

3

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

Fire

Electrical Shock

Toxic Fumes

Rotating Parts

Hot Surface

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
	Auto Start	Explosive Pressure	Chemical Burn	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
	Lift Hazard	Read Manual		reproductive harm. Wash hands after handling.
	The safety alert symbol indicates a potentialforpersonal
					WARNING Storage batteries give off explosive
	injury hazard. A signal word (DANGER, WARNING, or
					hydrogen gas during recharging.
	CAUTION) is used with the alert symbol to designate a
					Slightest spark will ignite hydrogen
	degree or level of hazard seriousness. A safety symbol
					and cause explosion, resulting in
	may be used to represent the type of hazard. The signal
					death or serious injury.
	word NOTICE is used to address practices not related to
	personal injury.	Not		Battery electrolyte fluid contains acid and is
	DANGER indicates a hazard which, if not avoided, will			extremely caustic.
	result in death or serious injury.			Contact with battery contents will cause severe
				chemical burns.
	WARNING indicates a hazard which, ifReprnot avoided, couldoduction
	result in death or serious injury.			A battery presents a risk of electrical shock and high short
				circuit current.
	CAUTION indicates a hazard which, if not avoided, could			• DO NOT dispose of battery in a fire. Recycle battery.
	result in minor or moderate injury.			• DO NOT allow any open flame, spark, heat, or lit cigarette
	NOTICE addresses practices not related to personal injury.				during and for several minutes after charging a battery.
	The manufacturer cannot possibly anticipate every possible			•	DO NOT open or mutilate the battery.
				•	Wear protective goggles, rubber apron, rubber boots and
	circumstance that might involve a hazard. The warnings in
	this manual, and the tags and decals affixed to the unit are,				rubber gloves.
	therefore, not all-inclusive. If you use a procedure, work			•	Remove watches, rings, or other metal objects.
	method or operating technique that the manufacturer does			•	Use tools having insulated handles.
	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.

4

	WARNING Generator produces hazardous voltage.				WARNING Propane and Natural Gas are extremely
	Failure to properly ground generator could result in				flammable and explosive, which could
	electrocution.				cause burns, fire or explosion resulting in
	Failure to isolate generator from utility power could				death or serious injury.
	result in death or serious injury to electric utility			•	DO NOT operate the equipment if the “fuel shut-off” valve
	workers due to backfeed of electrical energy.				is missing or inoperative.
•	When using generator for backup power, notify			•	Install the fuel supply system according to NFPA 37 and
	utility company.				other applicable fuel-gas codes.
•	DO NOT touch bare wires or bare receptacles.			•	Before placing the generator into service, the fuel system
•	DO NOT use generator with electrical cords which are				lines must be properly purged and leak tested.
	worn, frayed, bare or otherwise damaged.			•	After the generator is installed, you should inspect the fuel
•	DO NOT handle generator or electrical cords while				system periodically.
	standing in water, while barefoot, or while hands or feet			•	NO leakage is permitted.
	are wet.			•	DO NOT operate engine if smell of fuel is present or other
• If you must work around a unit while it is operating,
					explosive conditions exist.
	stand on an insulated dry surface to reduce the risk of a			•	DO NOT smoke around the generator. Wipe up any oil
	shock hazard.
					spills immediately. Ensure that no combustible materials
•	15 Amp fuse BEFORE working on the equipment.Reproduction
	DO NOT allow unqualified persons or children to operate				are left in the generator compartment. Keep the area near
	or service generator.				the generator clean and free of debris.
•	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				WARNING Starter and other rotating parts can
	the victim.	for			entangle hands, hair, clothing, or accessories
• Despite the safe design of the generator, operating this					resulting in serious injury.
	equipment imprudently, neglecting its maintenance			•	NEVER operate generator without protective housings,
	being careless can cause possible injury or death.
•	Remain alert at all times while working	this equipment.			covers, or guards in place.
	Never work on the equipment when you are physically or			•	DO NOT wear loose clothing, jewelry or anything that may
					be caught in the starter or other rotating parts.
	mentally fatigued.
•	Before performing any maintenance on the generator,			•	Tie up long hair and remove jewelry.
	disconnect the battery cable indicated by a NEGATIVE,			•	Before servicing, remove 15 Amp fuse from control panel
	NEG or (-) first. When finished, reconnect that cable last.				and disconnect Negative (NEG or -) battery cable.
•	After your system is installed, the generator may crank
	and start without warning anyNottime there is a power
	failure. To prevent possible injury, always set the				WARNING Unintentional sparking could cause fire or electric
	generator’s system switch to OFF, remove the service				shock resulting in death or serious injury.
	disconnect from the disconnect box AND remove the
				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.

5

	WARNING Exhaust heat/gases could ignite							CAUTION Excessively high operating speeds could
		combustibles or structures resulting in					result in minor injury.
		death or serious injury. Contact with muffler					Excessively low speeds impose a heavy load on generator.
		area could cause burns resulting in serious					•	DO NOT tamper with governed speed. Generator supplies
		injury.						correct rated frequency and voltage when running at
•	DO NOT touch hot parts and AVOID hot exhaust gases.							governed speed.
•	Allow equipment to cool before touching.						•	DO NOT modify generator in any way.
•	Exhaust outlet side of weatherproof enclosure must
	have at least 5 ft. (1.5 m) minimum clearance from any						NOTICE Improper treatment of generator can damage it
	structure, shrubs, trees or any kind of vegetation.						and shorten its life.
•	Standby generator weatherproof enclosure must be at						•	Use generator only for intended uses.
	least 5 ft. (1.5 m) from windows, doors, any wall opening,						•	If you have questions about intended use, contact your
	shrubs or vegetation over 12 inches (30.5 cm) in height.							authorized dealer.
•	Standby generator weatherproof enclosure must have a						•	Operate generator only on level surfaces.
	minimum of 5 ft. (1.5 m) overhead clearance from any						•	Adequate, unobstructed flow of cooling and ventilating air
	structure, overhang or trees.
								is critical to correct generator operation.
•	DO NOT place weatherproof enclosure under a deck or
							•	The Oil Fill, Oil Drain and the Control Panel doors must be
	other type of structure that may confine airflow.
								installed whenever the unit is running.
•	Use only flexible fuel line provided. Connect provided fuel
							•	DO NOT expose generator to excessive moisture, dust,
	line to generator, DO NOT use with or substitute any other
								dirt, or corrosive vapors.
	flexible fuel line.
							•	Despite the safe design of the generator, operating this
•			Reproduction
	Smoke detector(s) MUST be installed and maintained							equipment imprudently, neglecting its maintenance or
	indoors according to the manufacturer’s instructions/							being careless can cause possible injury or death.
	recommendations. Carbon monoxide alarms cannot						•	Remain alert at all times while working on this equipment.
	detect smoke.							Never work	the equipment when you are physically or
•	Keep at least minimum distances shown in General							mentally fatigued.
	Location Guidelines to insure for proper generator cooling						•	DO NOT start engine with air cleaner or air cleaner
	and maintenance clearances.							cover removed.
•	It is a violation of California Public Resource Code,						•	DO NOT insert any objects through cooling slots.
	Section 4442, to use or operate the engine			any	-		•	DO NOT use the generator or any of its parts as a step.
	covered, brush-covered, or grass-covered land unless
	the exhaust system is equipped with a spark arrester, as							Stepping	the unit can cause stress and break parts.
	defined in Section 4442, maintained in effectiveforestworking							This may result in dangerous operating conditions from
	order. Other states or federal jurisdictions may have							leaking exhaust gases, fuel leakage, oil leakage, etc.
	similar laws.						•	If connected devices overheat, turn them off and
	Contact the original equipment manufacturer, retailer, or							disconnect them from generator.
	dealer to obtain a spark arrester designed for the exhaust						Shut off generator if:
	system installed on this engine.
								-electrical output is lost;
•		Not
	Replacement parts must be the same and installed in the							-equipment sparks, smokes, or emits flames;
	same position as the original parts.
								-unit vibrates excessively:
								-unit makes unusual noises.
	CAUTION Installing the 15 Amp fuse could cause
	the engine to start at any time without warning
	resulting in minor or moderate injury.

•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.

6

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.

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

For the Installing Dealer/Contractor:

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.

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 U.S. Environmental Protection Agency and by the California Air Resources Board (CARB).

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
	loads in the event of failure of theReproductionnormal source negotiating with an installation professional. Remember
	to serve loads such as heating, refrigeration systems, and			For most applications, the installation manual contains
	communication systems that, when stopped during any			all the information required to properly install and start
	power outage, could cause discomfort or inconvenience.			the generator. This operator’s manual describes routine
				operation and owner maintenance procedures.
	NOTICE		for	If you need more information in this matter, please call at
		This product does NOT qualify for either an		800-732-2989 between 8:00 AM and 5:00 PM CT.
	emergency standby or legally required standby system as			Owner Orientation
	defined by NFPA 70 (NEC).
	• Emergency generator systems are intended to			This section provides generator owners with the information
	automatically supply illumination, power, both, to			necessary to achieve the most satisfactory and cost effective
				installation possible.
	designated areas and equipment in the event of failure
				The illustrations are for typical circumstances and are meant
	of the normal supply. Emergency systems may also
				to familiarize you with the installation options available
	provide power for such functions as ventilation where
				with your generator. A thorough understanding of these
	essential to maintain life, where current interruption
				options will provide fundamental control over the cost of
	of the normal supply would produce serious life
				your installation, as well as ensure your final satisfaction
	safety or health hazards.Not
				and security.
	• Legally Required standby generator systems are			Federal and local codes, appearance, noise levels, fuel types,
	intended to automatically supply power to selected			and distances are the factors that must be considered when
	which could create hazards or hamper rescue or fire-			that as the distance from the existing electrical service and
	fighting operations.			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.

7

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.		Reproduction
•	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%.			for
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					natural
		Not			this
or liquid propane gas. The emissions control system

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.

8

	Generator Location
							WARNING Running engine gives off carbon monoxide,
	The actual physical location of your generator has a direct						an odorless, colorless, poison gas.
	affect on:						Breathing carbon monoxide could result in death,
	1. The amount of plumbing required to fuel						serious injury, headache, fatigue, dizziness,
							vomiting, confusion, seizures, nausea or fainting.
		your generator.
					•	Operate this product ONLY outdoors in an area that will
	2.	The amount of wiring required to control and connect
						not accumulate deadly exhaust gas.
		your generator.			•	Keep exhaust gas away from any windows, doors,
	Specific location guidelines are discussed in the installation					ventilation intakes, soffit vents, crawl spaces, open garage
	manual. Acquaint yourself with that information and confer					doors or other openings that can allow exhaust gas
	with your installer. Be sure to ask how your site might					to enter inside or be drawn into a potentially occupied
	affect installation costs and compliance with local codes					building or structure.
					•	Carbon monoxide detector(s) MUST be installed and
	and standards.
	•	Install generator outdoors in an area that will not				maintained indoors according to the manufacturer’s
						instructions/recommendations. Smoke alarms cannot
		accumulate deadly exhaust gas.
						detect carbon monoxide gas.
	•	DO NOT install generator where exhaust gas could
		accumulate and enter inside or be drawn into a					WARNING Exhaust heat/gases could ignite
		potentially occupied building or structure.					combustibles or structures resulting in death or
	•	By law it is required in many states to have a Carbon					serious injury.
		Monoxide (CO) detector in operating condition in			•	Exhaust outlet side of weatherproof enclosure must
		your home. Carbon monoxide detector(s) (A) MUST
			Reproduction
		be installed and maintained indoors according to the				have at least 5 ft. (1.5 m) minimum clearance from any
		manufacturer’s instructions/recommendations. A CO				structure, shrubs, trees, or any kind of vegetation.
		monitor is an electronic device that detects hazardous			•	Standby generator weatherproof enclosure must be at
		levels of CO. When there is a buildup of CO, the				least 5 ft. (1.5 m) from windows, doors, any wall opening,
		monitor will alert the occupants by flashing visual				shrubs or vegetation over 12 in. (30.5 cm) in height.
				for	•	Standby generator weatherproof enclosure must have a
		indicator light and alarm. Smoke alarms cannot detect				minimum of 5 ft. (1.5 m) overhead clearance from any
		CO gas.				structure, overhang or trees.
		A			•	DO NOT place weatherproof enclosure under a deck or
			Not			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.

9

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)
Reproduction
		•	Torque screwdriver, 5 to 50 inch-pound range
		•	Voltage/frequency meter
		• Remote wireless monitor (OPTIONAL)
	for	• Antenna (OPTIONAL)
Not

10

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.

	E
					F
	D	Reproduction
	C				G
			for
	B
		Not			H
					J
	A
	Generator is shown with roof and access covers removed			(E) - Air Cleaner — Uses a dry type filter element and foam
	for clarity.			precleaner to protect engine by filtering dust and debris
	(A) - Lifting Holes — Provided at each corner for			out of intake air.
		lifting generator.		(F) - Control Panel — Used for various test, operation and
	(B) - Exhaust Port — High-performance muffler lowers			maintenance functions. See System Control Panel.
		engine noise to comply with most residential codes.		(G) - Circuit Breaker — Protects the system from shorts and
	(C) - Alternator — An electrical machine that generates an			other over-current conditions.
		alternating current.		(H) - Battery (installer supplied) — 12 Volt DC, top-post
	(D) - Spark Plug — A device in the cylinder head of the			automotive style battery provides power to start the
		engine that ignites the fuel mixture by means of an		engine.
		electric spark.		(J) - Fuel Inlet Port — Attach appropriate fuel supply to
				generator here.

11