Briggs & Stratton Elite 030210, Elite 30209 User Manual

Owner’s Manual

Manual del Propietario

Manual No. 195447GS

Revision 0 (07/29/2004)

Questions? Help is just a moment away!

Preguntas? La ayuda es justa un momento lejos!

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

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

030209

(5500W)

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

5500W Portable Generator

TABLE OF CONTENTS

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

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

Schematic/Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 16-17

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-22

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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 Generator”.

Every effort has been made to ensure that information in this manual is accurate and current. However,we reserve the right to change, alter or otherwise improve the product and this document at any time without prior notice.

The Emission Control System for this generator is warranted for standards set by the Environmental Protection Agency. For warranty information refer to the engine owner’s manual.

SAFETY RULES

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

The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION,WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. CAUTION, when 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.

Hazard Symbols and Meanings

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

Explosion

Toxic Fumes

Hot Surface

Electrical Shock

Electrocution

Electrical Shock

5500W Portable Generator

• Operate generator ONLY outdoors.

• 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

• 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

• 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

WHEN ADDING OR DRAINING FUEL

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

• Fill or drain fuel tank outdoors.

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

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

• DO NOT light a cigarette or smoke.

WHEN STARTING EQUIPMENT

• Ensure spark plug, muffler,fuel cap and air cleaner are in place.

• DO NOT crank engine with spark plug removed.

• If fuel spills, wait until it evaporates before starting engine.

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

5500W Portable 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.

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

Excessively low speeds impose a heavy load.

CAUTION

• 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 call 1-800-743-4115.

• Operate generator only on level surfaces.

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

• DO NOT insert any objects through cooling slots.

• If connected devices overheat, turn them off and disconnect them from generator.

• Shut off generator if:

-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.

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

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

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

• 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.

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

Severe burns can occur on contact. Combustible debris, such as leaves, grass, brush,

ect. can catch fire.

WARNING

5500W Portable Generator

120 Volt AC, 20 Amp, Duplex Receptacles — May be

used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting, appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle — May be used to supply electrical power for the operation of 120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz electrical, lighting, appliance, tool and motor loads.

Air Cleaner —

Protects engine by filtering dust and debris

out of intake air.

Choke Lever — Used when starting a cold engine. Circuit Breakers (AC) — Push to reset circuit breakers are

provided to protect the generator against electrical overload.

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

Fuel Tank — Capacity of seven (7) U.S. gallons. Grounding Fastener — If required, please consult a

qualified electrician, electrical inspector, or local agency having jurisdiction.

Oil Fill Cap/Dipstick — Check and fill engine with oil here.

Recoil starter — Used to start the engine. Rocker Switch — Set this switch to "On" before using

recoil starter. Set switch to "Off" to switch off engine.

KNOW YOUR GENERATOR

Read this owner’s manual and safety rules before operating your generator.

Compare this illustration with your generator to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference.

Fuel Tank

Air Cleaner

Rocker Switch

120/240 Volt AC, 30 Amp Receptacle

Circuit Breakers

Choke Lever

Recoil Starter

Grounding Fastener

Oil Fill Cap/Dipstick

120 Volt AC, 20 Amp Duplex Receptacles

Data Tag

5500W Portable Generator

ASSEMBLY

Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended oil and fuel.

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.

Remove Generator From Carton

1. Set the carton on a rigid flat surface with “This Side Up” arrows pointing upward.

2. Carefully open the top flaps of the shipping carton.

3. Cut down corners at one end of carton from top to bottom and lay that side of carton down flat.

4. Remove all packing material, carton fillers, etc.

5. Remove the generator from the shipping carton.

Carton Contents

Check all contents against those listed below:

• Main unit

• Engine oil

• Owner’s manual

• Engine manual

• Wheel kit If any parts are missing or damaged, call the generator helpline at 1-800-743-4115.

INSTALL WHEEL KIT

NOTE:While the wheel kit is designed to greatly improve

the portability of your generator, it is not intended for over-the-road use.

You will need two 1/2” or 13mm open end wrenches or a socket wrench with 1/2" or 13mm sockets and a needlenose pliers to install this kit.

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

1. Place the bottom of the generator frame on a flat, even surface.Temporarily place unit on blocks to ease assembly.

2. Slide axle through both axle mounting brackets on cradle frame, as shown in Figure 1.

3. Slide a wheel over the axle.

NOTE: Be sure to install wheel with raised hub inboard.

4. Slide a flat washer over the axle and place the e-ring onto the groove in the axle.

NOTE: Use retaining pins instead of e-clip, if applicable.

Capscrew

Handle

Mounting Leg

E-Ring

Wheel

Washer

Axle

Nut

Capscrew

Nut

Figure 1 — Install Wheel Kit

5500W Portable Generator

5. Place one end of the needle nose pliers on the bottom of the axle and the other end of the pliers on top of the e-ring. Seat the e-ring by pressing the pliers closed.

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

7. Remove the temporary blocks.

8. Attach support leg using two 1/2” or 13mm wrenches with 20mm cap screws and lock nuts.

9. Center lifting handle on generator end of cradle. Attach handle using two 1/2” or 13mm wrenches with 45mm capscrews and hex nuts.

BEFORE STARTING THE

ENGINE

Add Engine Oil

• Place generator on a level surface.

• Refer to engine owner’s manual and follow oil

recommendations and instructions.

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

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

Add Fuel

NOTE:This gasoline engine is certified to operate on

gasoline. Exhaust Emission Control System: EM (Engine Modifications).

1. Use clean, fresh,regular UNLEADED fuel with a minimum of 85 octane. DO NOT use fuel which contains Methanol. DO NOT mix oil with fuel.

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

3. Slowly add regular unleaded fuel to fuel tank. Be careful not to overfill.Allow about 1.5" of tank space for fuel expansion (Figure 2).

4. Install fuel cap and wipe up any spilled fuel.

CAUTION

• Refer to engine manual 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 before it has been properly filled with the recommended oil will result in equipment failure.

WHEN ADDING FUEL

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

• Fill fuel tank outdoors.

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

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

• DO NOT light a cigarette or smoke.

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WARNING

Fuel

Tank

1.5” Air Space

Figure 2 - Fuel Expansion

5500W Portable Generator

USING THE GENERATOR

System Ground

The generator has a system ground that connects the generator frame components to the ground terminals on the AC output receptacles.The system ground is connected to the AC neutral wire (the neutral is bonded to the generator frame).

Special Requirements

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

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

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

Connecting to a Building’s Electrical

System

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

OPERATING THE

GENERATOR

Starting the Engine

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

1. Make sure unit is on a level surface. IMPORTANT: Failure to start and operate unit on a level

surface will cause the unit not to start or shut down during operation.

2. Turn the fuel valve to the “On” position (Figure 3).The

fuel valve handle should be vertical (pointing toward the ground) for fuel to flow.

3. Start engine according to instructions given in the engine owner’s manual.

Fuel Valve is shown in the On position

Figure 3 — Fuel Valve

• 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

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

• Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area, such as metal decking or steel work.

• DO NOT touch bare wires or receptacles.

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

• DO NOT operate generator in the rain.

• 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

• Operate generator ONLY outdoors.

• 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

5500W Portable Generator

NOTE: If engine starts after 3 pulls but fails to run, or if unit shuts down during operation, make sure unit is on a level surface and check for proper oil level in crankcase. This unit may be equipped with a low oil protection device. See engine manual.

Connecting Electrical Loads

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

• Plug in and turn on the desired 120 and/or 240 Volt AC, single phase, 60 Hz electrical loads.

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

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

• DO NOT connect 50 Hz loads to the generator.

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

Stopping the Engine

1. Turn OFF and unplug all electrical loads from

generator panel receptacles. NEVER start or stop engine with electrical devices plugged in and turned ON.

2. Let engine run at no-load for several minutes to

stabilize internal temperatures of engine and generator.

3. Turn engine off according to instructions given in the

engine owner’s manual.

4. Move fuel valve to “Off” position.

RECEPTACLES

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA L14–30 plug with this receptacle. Connect a 4–wire cord set rated for 250 Volt AC loads at 30 Amps (or greater) (Figure 4).You can use the same 4–wire cord if you plan to run a 120 Volt load.

This receptacle powers 120/240 Volt AC, 60 Hz, single phase loads requiring up to 5,500 watts of power (5.5 kW) at 22.9 Amps for 240 Volts or two independent 120 Volt loads at 20 Amps each.The outlet is protected by push–to–reset circuit breakers.

• NEVER attempt to power a device requiring more amperage than generator or receptacle can supply.

• DO NOT overload the generator. See “Don’t Overload Generator”.

Receptacles may be marked with rating value greater than generator output capacity.

CAUTION

Figure 4 — 120/240 Volt AC, 30 Amp Receptacle

4-Wire Cord Set

240V

120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground (Green)

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

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

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

Severe burns can occur on contact. Combustible debris, such as leaves, grass, brush,

ect. can catch fire.

WARNING

5500W Portable Generator

120 Volt AC, 20 Amp, Duplex

Receptacles

Each duplex receptacle (Figure 5) is protected against overload by a push–to–reset circuit breaker.

Use each receptacle to operate 120 Volt AC, single–phase, 60 Hz electrical loads requiring up to 2,400 watts (2.4 kW) at 20 Amps of current. Use cord sets that are rated for 125 Volt AC loads at 20 Amps (or greater).

COLD WEATHER

OPERATION

Under certain weather conditions (temperatures below 40°F [4°C] and a high dew point), your generator may experience icing of the carburetor and/or the crankcase breather system.

Build a structure that will enclose three sides and the top of the generator:

1. Make sure entire muffler-side of generator is exposed. Note that your generator may appear different from that shown in Figure 6.

2. Ensure a minimum of two feet clearance between open side of box and nearest object.

3. Face exposed end away from wind and elements.

4. Enclosure should hold enough heat created by the generator to prevent problems.

Figure 6 — Permanent Cold Weather Shelter

Wind

• 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).

• Remove generator from shelter when temperature is above 40°F [4°C].

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

Breathing carbon monoxide will cause nausea, fainting or death.

DANGER

Figure 5 — 120 Volt, 20 Amp Duplex Receptacle

5500W Portable Generator

DON'T OVERLOAD

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 7.

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 7 - Wattage Reference Chart

+ 25 hidden pages