Briggs & Stratton PRO400, PRO4000 Operator's Manual

PRO4000PortableGenerator

Operator'sManual

This generator is rated and certified to becompliant with CSA (Canadian

Standards Association) standard 022.2 No. 100-04 (motors and generators).

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON, WISCONSIN, U.S.A.

Manual No. 204727GS

RevisionA (04/29/2009)

Thankyou for purchasing this quality-built Briggs & Stratton generator.We are pleasedthat you've placedyour confidencein the Briggs& Stratton brand. When operated and maintained according to the instructions in this manual,your Briggs & Stratton generatorwill provide many years of dependableservice.

Thismanualcontainssafety information to makeyou aware of the hazardsand risks associatedwith generators and how to avoid them. This generatoris designed and intendedonly for supplying electrical powerfor operating compatibleelectrical lighting, appliances,tools and motor loads, and is not intendedfor anyother purpose. It is important that you readand understand these instructions thoroughly before attempting to start or operatethis equipment. Save these instructionsfor

future reference.

Thisgenerator requiresfinal assemblybeforeuse. Referto the Assemb/ysection of this manualfor instructions on final assembly procedures. Follow the instructions completely.

Whereto FindUs

You never have to look far to find Briggs & Stratton support and service for your generator. Consultyour Yellow Pages.There are over 30,000 Briggs & Stratton authorized service dealersworldwide who provide quality service. You canalso contact Briggs & Stratton Customer Service by phone at (800) 743-4115, or on the Internet at BRIGGSandSTRATTON.COM.

Generator

Model Number Revision Serial Number

Engine

Model Number Type Number

Code Number

DatePurchased

Briggs & Stratton PowerProducts Group, LLC 900 North Parkway Jefferson, WI 53549

III

III III III

Copyright © 2009. All rights reserved.Nopart of this material may be reproducedor transmitted in anyform by any means without the expresswritten permission of Briggs & Stratton Power Products Group, LLC.

2 BRIGGSandSTRATTON.COIVl

Tableof Contents

Operator Safety ................................. 4

Equipment Description......................................... 4

Important Safety Information.................................... 4

Assembly ..................................... 7

UnpackGenerator ............................................ 7

Shipment Contents ........................................... 7

Install Wheel Kit.............................................. 7

Add Engine Oil............................................... 8

Add Fuel.................................................... 8

System Ground .............................................. 9

Connectingto aBuilding's Electrical System........................ 9

GeneratorLocation ........................................... 9

FeaturesandControls............................ 10

Cord Sets and Receptacles.................................... 11

Ground Fault Protection....................................... 12

Operation .................................... 13

Starting the Engine .......................................... 13

ConnectingElectrical Loads.................................... 13

Stopping the Engine.......................................... 14

OperatingAutomatic Idle Control................................ 14

Oil PressureShutdown ....................................... 14

Charginga Battery........................................... 14

ColdWeatherOperation....................................... 15

Don't OverloadGenerator ..................................... 16

Maintenance .................................. 17

MaintenanceSchedule........................................ 17

GeneratorMaintenance....................................... 17

FuelValveMaintenance....................................... 18

Engine Maintenance.......................................... 18

Storage ................................................... 21

Troubleshooting ................................ 22

Schematic ................................................. 23

Wiring Diagram ............................................. 24

Warranties .................................... 25

Emissions Control System Warranty ............................. 25

GeneratorOwnerWarranty .................................... 27

Specifications ................................. 28

Product Specifications........................................ 28

Common Service Parts ....................................... 28

Frangais Espa_ol

OperatorSafety

Equipment Description

Readthis manual carefully and becomefamiliar

...... with your generator. Knowits applications, its

limitationsand any hazardsinvolved.

Thegeneratoris anengine-driven, revolvingfield, alternating current (AC) generator. It was designedto supply electrical power for operatingcompatible electricallighting, appliances, tools and motor loads.Thegenerator's revolving field is driven at about3,600 rpm by a single-cylinderengine.

This generator incorporates GFCI(Ground Fault Circuit Interrupter) outlet protection andhas its neutral bonded to ground to comply to OSHAinspections on job sites. This generatorwill not function when connectedto a 2 pole transfer switch sincethe home or building main breaker box also has a neutral bondedto ground. When both the generator andthe home or building breakerbox contains a neutral bonded to ground, the generatorsGFCIwill open and

no outlets will function.

_i, WARNING Removingthe neutral bond could resultin

_1_ death, bodily injury and/or propertydamage.

• DONOTremovetheneutralbond.

Important Safety Information

Themanufacturer cannot possibly anticipateevery possible circumstance that might involve a hazard.Thewarnings in this manual, and the tags and decals affixedto the unit are, therefore, not all-inclusive. Ifyou usea procedure,work method or operating technique that the manufacturer does not specifically recommend, you must satisfy yourself that it is safe for you andothers. You must also makesure that the procedure, work method or operating technique that you choose does not renderthe generator unsafe.

SafetySymbolsand Mleanings

Toxic Fumes Kickback ElectricalShock

Fire Explosion Operator'sManual

Moving Parts FlyingObjects Hot Surface

NOTICE Exceedinggeneratorswattage/amperagecapacity candamagegenerator and/or electrical devices connectedto

it.

• DONOTexceedthegenerator'swattage/amperagecapacity.See Don'tOverloadGeneratorinthe Operationsection.

Everyeffort hasbeen madeto ensurethat the information in this manual is both accurateand current. However,the manufacturer reservesthe right to change,alter or otherwise improve the generator and this documentation at anytime without prior notice.

The EmissionControl System for this generator is warranted for standardsset by the Environmental Protection Agency

and the California Air ResourcesBoard.

,lib

ExplosivePressure

,A Thesafety alert symbol indicates a potential personal

injury hazard.A signal word (DANGER,WARNING,or CAUTION)is usedwith the alert symbol to designatea degreeor levelof hazardseriousness.A safety symbol may be usedto representthe type of hazard.Thesignal word

NOTICEis usedto address practicesnot relatedto personal

injury. _i, DANGER indicates a hazardwhich, if not avoided, will

result in deathor serious injury.

_i, WARNINGindicates a hazardwhich, if not avoided,

could result indeath or serious injury.

_i, CAUTIONindicates ahazardwhich, if not avoided, could

result in minor or moderate injury.

NOTICEaddress practices not related to personal injury.

ChemicalBurn

4 BRIGGSandSTRATTON.COIVl

Using a generator indoors CAN KiLL YOU iN MINUTES,

Generator exhaust contains carbon monoxide, This is

a poison you cannot see or smell,

_i, WARNING Starter cord kickback (rapid retraction) can

result in bodily injury. Kickback will pull hand

_ and arm toward engine faster than you can let

go.

Broken bones, fractures, bruises, or sprains could result.

• When starting engine, pull cord slowly until resistanceisfelt andthen pull rapidlyto avoid kickback.

• NEVERstart or stop enginewith electricaldevices plugged in andturned on.

V V

NEVER use inside a home

or garage, EVEN iF doors and windows are open,

_i, WARNING Running engine gives off carbon

monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause headache,

fatigue, dizziness, vomiting, confusion, seizures,

nausea, fainting or death.

• Operategenerator ONLYoutdoors.

• Install a battery operatedcarbon monoxidealarm nearthe bedrooms.

• Keepexhaustgas from entering a confinedareathrough windows, doors,ventilation intakes, or other openings.

• DO NOTstart or run engine indoors or in an enclosedarea, (even if windows anddoors are open), including the generator

compartment of arecreational vehicle (RV).

Only use OUTSIDE and far away from windows,

doors, and vents,

_i, WARNING Storage batteriesgive off explosive

_,il;,_ ,,-_.._.hydrogen gas during recharging.

,t_,,_._,, _ Hydrogengasstays nearbatteryfor a

long time after battery has beencharged.

Slightest spark will ignite hydrogen and cause explosion. You can be blinded or severelyinjured.

Batteryelectrolytefluid contains acid and is extremely caustic.

Contactwith batteryfluid will causeseverechemicalburns.

• DONOTallowanyopenflame,spark,heat,orlitcigarette duringandfor severalminutesaftercharginga battery.

• Wearprotectivegoggles,rubberapron,andrubbergloves.

A, WARNING Theengineexhaustfrom this product contains chemicals known to the State of Californiato

causecancer, birth defects,or other reproductive harm.

_i, WARNING Certain components in this product and relatedaccessoriescontain chemicals known to the State

of Californiato causecancer, birth defectsor other reproductive harm. Washhands after handling.

_i, WARNING Fuel and its vapors are extremely

flammable and explosive.

Fire or explosion can cause severe burns or death.

WHENADDINGOR DRAININGFUEL

• Turn generator OFFand let it coolat least2 minutes before removing fuel cap. Loosen cap slowly to relievepressure in

tank.

• Fill or drain fuel tank outdoors.

• DONOToverfill tank. Allow spacefor fuel expansion.

• Iffuel spills,wait until it evaporatesbefore starting engine.

• Keepfuel awayfrom sparks, open flames, pilot lights, heat, and other ignition sources.

• DONOTlight a cigaretteor smoke.

WHENSTARTINGEQUIPMENT

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

• DO NOTcrank enginewith spark plug removed.

WHENOPERATINGEQUIPMENT

• DONOTtip engine or equipmentat angle which causesfuel to spill.

• This generator is not for use in mobile equipment or marine applications.

WHENTRANSPORTING,MOVINGOR REPAIRINGEQUIPMENT

• Transport/move/repair with fuel tank EMPTYor with fuel shutoff valveOFF.

• DONOTtip engine or equipmentat angle which causesfuel to spill.

• Disconnectspark plug wire.

WHENSTORINGFUELOR EQUIPMENTWITH FUEL IN TANK

• Store away from furnaces, stoves, water heaters,clothes dryers, or otherappliancesthat havepilot light or other ignition source becausethey can ignite fuel vapors.

A WARNING

• This generator does notmeet U. S. CoastGuardRegulation 33CFR-183and should not beusedon marineapplications.

• Failureto usethe appropriate U. S.CoastGuard approved generator could result in deathor serious injury and/or property damage.

_i, WARNING Generator produces hazardous voltage.

'),111, Failure to isolate generator from power utility

can result in death or injury to electric utility workers due to backfeed of electrical energy.

• When using generator for backup power, notify utility company. Use approvedtransfer equipment to isolategeneratorfrom electric utility.

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

• DO NOTtouch barewires or receptacles.

• DO NOTuse generator with electrical cords which areworn,

frayed, bareor otherwisedamaged.

• DO NOToperate generator in the rain or wet weather.

• DO NOThandle generator or electricalcords while standing in water, while barefoot,or while hands or feet are wet.

• DO NOTallow unqualified personsor children to operate or servicegenerator.

_i, WARNING Contact with muffler area can result in

serious burns. Exhaust

combustibles, structures or damage

fuel tank causing a fire.

• DO NOTtouch hot parts andAVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keepat least5 feet (152 cm) of clearanceon all sidesof generator including overhead.

• It is aviolation of California Public Resource Code,Section 4442, to use or operate the engineon any forest-covered, brush-covered, or grass-covered land unlessthe exhaust system is equipped with aspark arrester, as defined in Section 4442, maintained in effective working order. Otherstates or

federal jurisdictions may have similar laws.

Contactthe original equipment manufacturer, retailer, or dealer

to obtain a sparkarrester designed for the exhaust system

installed on this engine.

• Replacement parts must bethe same and installed inthe same position asthe original parts.

heat/gases can ignite

_i, CAUTION Excessively high operating speeds increase

risk of injury and damage to generator.

Excessively low speeds impose a heavy load.

• DO NOTtamper with governedspeed. Generatorsupplies correct rated frequency and voltage when running at governed speed.

• DO NOTmodify generator in any way.

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

it.

• DO NOTexceedthe generator's wattage/amperage capacity. See Don't OverloadGeneratorin the Operationsection.

• Start generator and let engine stabilize beforeconnecting electrical loads.

• Connectelectrical loadsin OFFposition, thenturn ONfor operation.

• Turn electrical loads OFFand disconnect from generator before stopping generator.

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

• Use generator only for intended uses.

• If you havequestions about intended use,ask dealeror contact local service center.

• Operategenerator only on level surfaces.

• DO NOTexpose generator to excessivemoisture, dust, dirt, or corrosive vapors.

• DO NOTinsert any objects through cooling slots.

• If connected devicesoverheat, 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.

_i, WARNING Unintentional sparking can result in fire or

_ electric shock.

WHENADJUSTINGOR MAKINGREPAIRSTO YOURGENERATOR

• Disconnectthe spark plug wire from the spark plug and place the wire where it cannot contact spark plug.

WHENTESTINGFORENGINESPARK

• Use approved spark plug tester.

• DO NOTcheck for spark with spark plug removed.

_i, WARNING Starter and other rotating parts can

entangle hands, hair, clothing, or accessories.

• NEVERoperategeneratorwithout protective housing or covers.

• DO NOTwear looseclothing, jewelry or anythingthat may be

caught in thestarter or other rotating parts.

• Tie up long hairand removejewelry.

6 BRIGGSandSTRATTON.COIVI

Assembly

Your generator requiressome assembly and is readyfor use after it hasbeen properly servicedwith the recommended oil

and fuel. If you haveany problemswith the assemblyof your generator,

pleasecall the generator helplineat (800)743-4115. If calling for assistance,pleasehavethe model,revision,andserial

numberfrom the identificationlabelavailable.SeeControls and Featuresfor identificationlabel location.

UnpackGenerator

1. Setthe carton on a rigid, flat surface.

2. Removeeverything from carton except generator.

3. Opencarton completely by cutting each corner from top to bottom.

4. Leavegeneratoron cartonto install wheel kit.

Install Wheel Kit

NOTICE Wheel kit is not intended for over-the-road use. You will needthe following tools to install these

components:

• 3/8" and 13 mmwrench

• Socketwrench with a 3/8" and 13mm socket

• Pliers

• Safetyglasses

Installthewheelkit asfollows:

1. Tip generatorso that engineend is up.

2. Slide axle (A) through both mounting brackets.

3. Slide a wheel (B) over axle.

NOTICE Besure to install wheelwith raised hub inboard.

4. Placea washer (C) on axleandthen placean e-ring (D) in axle groove.

Shipment Contents

The generatoris suppliedwith:

• Engineoil

• Operator's manual

• Batterycharge cables

• Wheelkit

• 120/240 Volt, 20 Amp locking plug

• 120Volt, 30Amp locking plug

_i, CAUTION E-rings can causeeye injury.

E-rings can spring back and become airborne when installing or removing.

• Alwaysweareyeprotectionwheninstalling/removinge-rings.

5. Install e-ring with pliers, squeezingfrom top of e-ring to bottom of axle.

6. Repeatsteps 3 through 5 to securesecondwheel.

7. Tip generatorso that engineside is down.

8. Attach clamps (E) to brackets (F) on both sides of generatorwith 1/4' - 20 hexscrews (G).

9. Repeatsteps 2 through 5 to securethe third and fourth wheels.

10.Attachhandle(H)tobracketongeneratorframeas shown,witha50mmcapscrew(J),flatwashers(K),

nylonwashers(L),andM8locknut(M).

NOTICE DO NOTovertighten. Handlemust beable to move up and down freely.

11. Return generator to normal operating position (resting on wheels).

12. To apply brakes,push down firmly on handle of both clamps until it locks in the down position andengages

the wheels.

NOTICE The generator is designedto be used on level surfaces.

13. Loop handlepin (N) on generatorframe just above handle bracket.

14. Raise handleand insert handlepin to movegenerator.

15. To releasebrakes,pull up on handle of both clamps until it locks in the up position.

Add Engine Oil

1. Placegeneratoron a flat, levelsurface.

2. Cleanarea around oil fill andremoveyellow oil fill cap.

3. Using oil funnel (optional), slowly pour contents of provided oil bottle into oil fill opening.

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

• DO NOTattempt to crank or start the engine beforeit has been properly servicedwith the recommended oil. This may result in an enginefailure.

_i, WARNING Fueland its vapors are extremely

flammable and explosive.

_, _ Fire or explosion can causesevere

burns or death.

WHENADDINGFUEL

• Turn generator OFFand let it cool at least2 minutes before removing fuel cap. Loosen cap slowly to relievepressure in

tank.

• Fill fuel tank outdoors.

• DONOToverfill tank. Allow spacefor fuel expansion.

• Iffuel spills,wait until it evaporatesbefore starting engine.

• Keepfuel awayfrom sparks, open flames, pilot lights, heat, and other ignition sources.

• DONOTlight a cigaretteor smoke.

To protectthe fuelsystemfrom gum formation, mix ina fuel stabilizerwhen addingfuel. SeeStorage.All fuel is not the same.Ifyou experiencestartingor performanceproblems after usingfuel,switch to adifferentfuel provideror changebrands. This engineis certified to operateon gasoline.Theemission control systemfor this engineis EM(EngineModifications).

1. Cleanarea around fuel fill cap,remove cap.

2. Slowly addunleadedgasoline (A) to fuel tank (B). Be careful not to fill abovethe baffle (C). This allows adequatespace for fuel expansion as shown.

4. Replaceoil fill cap and fully tighten.

Add Fuel

Fuel must meet theserequirements:

• Clean,fresh, unleadedgasoline.

• A minimum of 87 octane/87AKI (91 RON).High altitude use, seeHigh Altitude.

• Gasolinewith up to 10% ethanol (gasohol) or up to 15% MTBE(methyl tertiary butyl ether) is acceptable.

NOTICE Avoid generatordamage. Failureto follow Operator's Manualfor fuel

recommendations voids warranty.

• DONOTuseunapprovedgasolinesuchasE85.

• DONOTmixoilin gasoline.

• DONOTmodifyengineto runonalternatefuels.

3. Install fuel capand let any spilled fuel evaporatebefore starting engine.

High Altitude At altitudes over 5,000 feet (1524 meters), a minimum

85 octane/ 85 AKI (89 RON)gasoline is acceptable.To

remainemissions compliant, high altitude adjustment is

required.Operationwithout this adjustment will cause decreasedperformance, increasedfuel consumption, and increasedemissions. Seea Briggs & Stratton Authorized

Dealerfor high altitude adjustment information. Operation of the engine at altitudes below 2,500 feet (762 meters) with the high altitude kit is not recommended.

8 BRIGGSandSTRATTON.COIVl

SystemGround

Thegenerator hasa system ground that connectsthe generatorframe components to the ground terminals onthe ACoutput receptacles.Thesystem ground is connected to the ACneutral wire (the neutral is bonded to the generator frame).

GeneratorLocation

Clearancesand Air Movement

_i, WARNING Exhaustheat/gases can ignite

combustibles, structures or damagefuel tank causing a fire.

Special Requirements

Theremay be Federalor State OccupationalSafety and Health Administration (OSHA)regulations, local codes, or ordinances that applyto the intended useof the generator. Pleaseconsult a qualified electrician, electrical inspector, or the local agency having jurisdiction:

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

• Ifthe generator is usedat a construction site, there may be additional regulations which must be observed.

Connecting to a Building's Electrical System

Connectionsfor standby powerto a building's electrical system must be made by a qualified electrician. The connection must isolate the generator powerfrom utility power or other alternativepower sources andmust comply with all applicablelaws andelectrical codes.

A, WARNING Generatorproduces hazardousvoltage.

')Jib Failureto isolate generatorfrom power utility

can result in deathor injury to electric utility workers due to backfeedof electrical energy.

• Whenusinggeneratorfor backuppower,notifyutilitycompany. Useapprovedtransferequipmentto isolategeneratorfrom electricutility.

• Useagroundfaultcircuitinterrupter(GFCI)in anydampor highlyconductivearea,suchas metaldeckingor steelwork.

• DONOTtouchbarewiresor receptacles.

• DONOTusegeneratorwithelectricalcordswhichareworn,

frayed,bareorotherwisedamaged.

• DONOToperategeneratorintherainorwetweather.

• DONOThandlegeneratoror electricalcordswhilestandingin water,whilebarefoot,or whilehandsorfeetarewet.

• DONOTallowunqualifiedpersonsor childrento operateor servicegenerator.

• Keepatleast5 ft. (152cm) clearanceonall sidesof generator includingoverhead.

Placegenerator outdoors in an areathat will not accumulate deadlyexhaust gas. DONOTplace generatorwhere exhaust gas (A) could accumulate and enter inside or be drawn into a potentially occupied building. Ensureexhaustgas is kept awayfrom any windows, doors, ventilation intakes, or other openings that canallow exhaust gasto collect in a confined area.Prevailingwinds and air currents should betaken into consideration when positioning generator.

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell.

V V

NEVER use insidea home or garage, EVENIF doors

and windowsare open.

Only use OUTSIDE and far away from windows, doors, and vents.

FeaturesandControls

Readthis Operator'sManualand safetyrules beforeoperatingyourgenerator.

Comparethe illustrations with your generator,to familiarize yourself with the locations of various controls and adjustments. Savethis manual for future reference.

A- FuelTank -- Capacityof four and a half (4.5) U.S.

gallons.

B- Oil Fill Cap/Dipstick-- Checkand add engineoil here. C- Fuel Valve-- Usedto turn fuel supply on and off to

engine. D - Oil DrainPlug -- Drainengine oil here. E - Spark ArrestorMuffler -- Exhaust muffler lowers engine

noise and is equipped with a spark arrestor screen. F - Rocker Switch -- Set this switch to run (I) before using

recoil starter. Setswitch to stop (0) to stop engine. G - ChokeLever- Usedwhen starting a cold engine. H - Engine Identification -- Provides model, type and code

of engine. Pleasehavethesereadily availableif calling for assistance.

J - Air Cleaner-- Protectsengine by filtering dust and

debris out of intake air.

K- Recoil Starter -- Usedto start the engine. L - Data Tag - Provides model, revision and serial number

of generator. Pleasehavethese readilyavailableif calling

for assistance.

M - GroundingFastener-- If required, pleaseconsult a

qualified electrician, electrical inspector, or local agency havingjurisdiction.

N - Idle ControlSwitch -- Usethis switch to turn the idle

control feature on andoff.

P - 12 Volt DC Receptacle -- Usethis receptaclewith

batterycharge cablesto chargea 12Volt battery.

R - 120Volt AC, 20 Amp DuplexReceptacle-- May be

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

S - 120 Volt AC,30 AmpLockingReceptacle -- May be

usedto supply electrical power for the operation of 120 Volt AC, 30 Amp, single phase, 60 Hzelectrical lighting, appliance,tool and motor loads.

T - 120/240 Volt AC,20 AmpLockingReceptacle-- May

be usedto supply electrical power for the operation of 120 and/or 240Volt AC,20 Amp,single phase,60 I-Iz electrical lighting, appliance,tool and motor loads.

V - GFClCircuitBreaker-- A GFCIcircuit breakeris

providedto protect against electricalground fault and protect the generatoragainst electrical overload.

W - Hour Meter- Displays and records how many hours

your generatorhas run (up to 9,999.9).

10 BRIGGSandSTRATTON.COM

CordSetsandReceptacles

Use only high quality, well-insulated, grounded extension cords with the generator's 120 Volt duplex receptacle. Inspect extension cords before eachuse.

Checkthe ratings of all extensioncords beforeyou use them. Extensioncord sets usedshould be rated for 125 Volt

ACloads at 20 Amps or greaterfor most electrical devices. Somedevices,however, may not require this type of extension cord. Checkthe operator's manuals of those

devicesfor the manufacturer's recommendations. Keepextension cords asshort aspossible to minimize

voltage drop.

120 Volt AC, 30 Amp LockingReceptacle

Usea NEMA L5-30 plugwith this receptacle.Connecta 3-wire cord set ratedfor 125 Volt ACloads at 30 Amps to the plug.

_'ireCord Set

NEMA L5-30

Neutral

® ®

120V Hot

_i, WARNING Overloadedelectrical cords can overheat,

arc, and burn resulting in death, bodily injury, and/or property damage.

• ONLYusecordsratedfor yourloads.

• Followallsafetiesonelectricalcords.

120/240 Volt AC, 20 Amp, LockingReceptacle Use a NEMAL14-20 plugwith this receptacle.Connecta

4-wire cord set rated for 250 Volt AC loadsat 20 Amps (or greater). You can usethe same4-wire cord if you planto run

a 120 Volt load.

I 4-Wire CordSet

(Neutral)

Y (Hot)

NEMA L14-20

This receptaclepowers 120/240 Volt AC, 60 Hz,single phase loads requiring up to 4,000 watts of power (4.0 kW) at

16.6 Amps for 240 Volts or two independent 120 Volt loads at 16.6 Amps each. Theoutlet is protected by a2 pole GFCI

circuit breaker.

F7L7 X (Hot)

Ground (Green)

II11111111111

(Green)

Usethis receptacleto operate120 VoltAC,60 Hz,singlephase loadsrequiringup to 3,600watts (3.6kW)of powerat30 Amps.Theoutlet is protectedby a 2 pole GFCIcircuit breaker.

120 Volt AC, 20 Amp, DuplexReceptacles Theduplex receptacleis protected against overload by a

2 pole GFCIcircuit breaker.

Useeachreceptacleto operate 120 Volt AC, single-phase, 60 Hz electricalloads requiring upto 2,400 watts (2.4 kW) at 20 Amps of current. Usecord sets that are ratedfor 125 Volt ACloads at 20 Amps (or greater). Inspect cord sets before

eachuse. 12 Volt DC,10 AmpReceptacle

This receptacleallows you to rechargea 12 Volt automotive or utility style storagebatterywith the battery charge cables provided.

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

• NEVERattempt to power adevice requiring moreamperagethan generator or receptacle can supply.

• DONOToverloadthe generator. SeeDon't OverloadGenerator.

This receptaclecan not recharge6 Volt batteriesand can not be usedto crank anengine having adischarged battery. See the section Charginga Batterybefore attempting to recharge a battery.

Ground Fault Protection

This unit is equippedwith a Ground Fault Circuit Interrupter (GFCI).This device meets applicablefederal, stateand local

codes. The GFCIprotects against electrical shockthat may be

caused if your body becomes a pathwhich electricity travels to reachground. This could happenif you touch a"Live" applianceor wire, or aretouching plumbing or other materials that connectto the ground.

When protected by a GFCI,one may still feel a shock, but the GFCIshould cut current off quickly enough so that aperson in normal healthshould not suffer anyserious electrical injury.

_k WARNING Generator produces hazardous

_ voltage/current.

• TheGFCIwill not protect you againstthe following situations:

-Line-to-line shocks;

-Current overloadsor line-to-line short circuits.

• Thefuse or circuit breakeratthe control panel must provide such protection.

DuringGeneratorUse

If circuit breakertrips during use,it usually indicates faulty electrical equipment or cords. However,test the circuit breakeras follows;

1. Disconnect loads, reset and test circuit breakeras described earlier. Let generator runwithout any loads

for 1 minute.

_k CAUTION If circuit breaker trips in the 1 minute period:

• DONOTusegenerator.

• Calla Briggs& StrattonPowerProductsservicecenter.

If circuit breakertests correctly, the electrical equipment or extension cords may befaulty. Replace faulty electrical equipment andcords beforefurther

use.

A. CAUTION If circuit breaker tests correctly:

• Havequalified personnel checkall electricalequipment and cords for any defects.

• Replaceelectricalequipment and cords or taketo a qualified repair center.

TestGFCICircuit Breaker

Testyour GFCIcircuit breaker every month, as follows:

1. While generator is running, push white "Test" button. Thecircuit breakershould trip (handle will move to approximate center position), which will disconnect power to outlets.

_k CAUTION If circuit breaker does not trip:

• DONOTusegenerator.

• Calla Briggs& StrattonPowerProductsservicecenter.

2. If handlemoves to center, resetcircuit breakerby firmly moving handleto "Off" (down) position, then to "On" (up) position.

_k WARNING Generator produces hazardous

_1_ voltage/current.

• DO NOTtouch barewires or receptacles.

• DO NOTuse generator with electrical cords which areworn, frayed,bare or otherwisedamaged.

• DO NOToperate generator in the rain or wet weather.

• DO NOThandle generator or electricalcords while standing in water, while barefoot,or while hands or feet arewet.

• DO NOTallow unqualified personsor children to operate or servicegenerator or electrical loads.

_k CAUTION If circuit breaker does not reset properly:

• DO NOTuse generator.

• Calla Briggs & Stratton Power Productsservice center.

12 BRIGGSandSTRATTON.COIVI

Operation

Starting the Engine

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

1. Make sure unit is on a level surface.

NOTICE Failureto start and operatethe unit on a level surfacewill causethe unit not to start or shut down during

operation.

2. Turn thefuel valve (A) to the "On" position.

3. Make sure idle control switch is in "Off" position.

IDLE CONTROL

4. Push engine rocker switch to run position(I).

5. Push choke lever (B)to "Choke" position.

7. Move choke leverto "Half" choke position, and pull recoil handletwice.

• If engine fails to start, repeatsteps 5 thru 6.

8. Slowly movechoke leverto "Run" position. If engine falters, move choke lever to "Half" choke position until engine runs smoothly, and then to "Run" position.

NOTICE If engine floods, move choke lever to "Run" position and crank until enginestarts.

NOTICE If engine starts after 3 pulls but fails to run, or if unit shuts down during operation, makesure unit is on a level surfaceand check for proper oil level in crankcase.This unit may be equipped with a low oil protection device. If so, oil must beat proper levelfor engine to start.

_i, WARNING Contact with muffler area can result in

serious burns. Exhaust heat/gases can ignite

combustibles, structures or damage

fuel tank causing a fire.

• DO NOTtouch hot parts andAVOIDhot exhaust gases.

• Allow equipmentto cool beforetouching.

• Keepat least5 feet (152 cm) of clearanceon all sides of generator including overhead.

• It is aviolation of California Public Resource Code,Section 4442, to use or operate the engine on any forest-covered,

brush-covered, or grass-covered land unless the exhaust system is equipped with aspark arrester, as defined in Section

4442, maintained in effective working order. Other states or federaljurisdictions may have similar laws.

Contactthe original equipment manufacturer, retailer, or dealer to obtain aspark arrester designed for the exhaust system

installed on this engine.

• Replacement parts must bethe same and installed inthe same position asthe original parts.

._Z Ikl Itl

6. Grasp recoil handleand pull slowly until slight resistance is felt. Then pull rapidly one time only to start engine.

• If engine starts, proceedto step 8.

• If engine fails to start, proceedto step 7.

_i, WARNING Starter cord kickback (rapid retraction)can

result in bodily injury. Kickbackwill pull hand

llii_ - andarm toward enginefasterthan you can let

T-"

go.

Broken bones,fractures, bruises, or sprains could result.

• Whenstartingengine,pullcordslowlyuntilresistanceisfelt andthenpullrapidlytoavoidkickback.

• NEVERstartor stopenginewith electricaldevicespluggedin andturnedon.

Connecting Electrical Loads

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

2. Plug inand turn on the desired 120 and/or 240 Volt

AC,single phase,60 Hzelectrical loads.

NOtiCE

• DONOTconnect 240 Volt loads to the 120 Volt duplex receptacles.

• DONOTconnect 3-phaseloads to the generator.

• DONOTconnect 50 Hzloadsto the generator.

• DONOTOVERLOADTHEGENERATOR.SeeDon't

OverloadGenerator.

NOTICE Exceeding generators wattage/amperage capacity

can damage generator and/or electrical devices connected to it.

• DO NOTexceedthe generator's wattage/amperage capacity. See Don't OverloadGeneratorin the Operationsection.

• Start generator and let engine stabilize beforeconnecting electrical loads.

• Connectelectrical loads in OFFposition, thenturn ONfor operation.

• Turn electrical loads OFFand disconnect from generator before stopping generator.

Stoppingthe Engine

1. Turn OFFand unplug all electrical loads from generator panel receptacles.NEVERstart or stop enginewith electrical devicesplugged in and turned ON.

2. Move idle control switch to "Off" position.

3. Let engine run at no-loadfor severalminutes to stabilize internaltemperatures of engineand generator.

4. Push engine rocker switch to stop position (0).

_i, WARNING Backfire,fire or engine damagecould

occur.

_i, WARNING Storage batteriesgive off explosive

,- hydrogen gasduring recharging.

_'_ Hydrogen gas stays near battery for a

long time after battery has beencharged.

Slightest spark will ignite hydrogen and cause explosion. You can be blinded or severelyinjured.

Batteryelectrolytefluid contains acid and is extremely

caustic. Contactwith batteryfluid will causeseverechemical burns.

• DONOTallowanyopenflame,spark,heat,orlitcigarette duringandfor severalminutesaftercharginga battery.

• Wearprotectivegoggles,rubberapron,andrubbergloves.

• DONOTstop engine bymoving chokecontrol to "Choke" position (]",l ).

5. Move fuel valve to "Off" position.

Operating Automatic Idle Control

This feature is designedto greatly improve fuel economy. When this switchis turned ON,the enginewill only run at its normal high governedengine speed when electrical loads

are connected.When electrical loads are removed,the engine will run at a reducedspeed.

With the switchoff, the enginewill run at the normal high engine speed.Alwayshave the switchoff whenstartingand

stoppingthe engine.

Oil Pressure Shutdown

If engine oil pressuredrops below a preset level,an oil switch will stop the engine. Checkoil levelwith dipstick.

If oil level isbetweenADDand FULLmark on dipstick:

1. DONOTtry to restart the engine.

2. Contact a Briggs & Stratton Authorized Dealer.

3. DONOToperate engine until oil pressureis corrected.

To recharge12 Volt batteries, proceed asfollows:

1. Checkfluid levelin all battery cells. If necessary,add ONLYdistilled water to cover separators in battery cells. DONOTusetapwater.

2. If batteryis equippedwith vent caps, make sure they are installed and aretight.

3. If necessary,clean batteryterminals.

_i, WARNING Battery posts, terminals and related accessoriescontain leadand leadcompounds - chemicals

known to the State of Californiato cause cancerand

reproductiveharm. Wash handsafter handling.

4. Connectbattery chargecable connector plug to panel receptacleidentified by the words "12V IOA D.C."

5. Connectbattery chargecable clamp with red handleto the positive(+) batteryterminal.

12 VOLT D.C.

RECEPTACLE

If oil level is

Add oil to bring level to FULLmark.

Restart engine and if the engine stops again a low oil

belowADDmark on dipstick:

pressure condition may still exist. DONOTtry to restart the engine.

Contact a Briggs & Stratton Authorized Dealer.

DONOToperateengine until oil pressure is corrected.

Charging a Battery

Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage battery.

• DONOTuse the unit to charge any 6 Volt batteries.

• DONOTuse the unit to crank an engine having a discharged battery.

14 BRIGGSandSTRATTON.COIVl

POS NEG

6. Connectbattery chargecable clamp with blackhandle to the negative(-) battery terminal.

7. Start engine. Let engine run while battery recharges.

8. When battery hascharged, shut down engine.

NOTICE Use an automotive hydrometerto test batterystate of charge and condition. Follow the hydrometer

manufacturer's instructions carefully. Generally,a battery is considered to be at 100% stateof charge when specific

gravity of its fluid (as measured by hydrometer) is 1.260 or higher.

Cold WeatherOperation

Under certain weather conditions (temperatures below 40°F [4°0] combined with high humidity), your generator may experienceicing of the carburetor and/or the crankcase breather system. To reduce this problem, you needto perform the following:

1. Make sure generator hasclean,fresh fuel.

2. Openfuel valve(turn valve to open position).

3. Use SAE5W-30 oil.

4. Checkoil leveldaily or after every eight (8) hours of operation.

5. Maintain generatorfollowing MaintenanceSchedulein

Maintenancesection.

6. Shelter unit from elements.

Creatinga TemporaryColdWeather Shelter

1. Fortemporary shelter,the original shipping carton can be used.

2. Cut off top cartonflaps andone long sideof carton to expose muffler side of unit. If required,tape up other sides of carton to fit over generatoras shown.

Wind

Typical Generator

Shown

NOTICE If required, removewheel kit to fit carton over generator asshown.

3. Cut appropriate slots to access receptaclesof unit.

4. Faceexposedend away from wind and elements.

5. Locate generatoras described in the section Generator Location. Keepexhaust gasfrom entering aconfined areathrough windows, doors, ventilation intakes or other openings.

Start generator as described in the section Starting the Engine,then placecarton over generator. Keepat least

5 ft. (1.5 m) clearanceon all sides of generator including overheadwith shelter in place.

A WARNING Contactwith muffler area can result in

serious burns. Exhaust

heat/gases can ignite

combustibles, structures or damage

fuel tank causinga fire.

• DONOTtouchhotpartsandAVOIDhot exhaustgases.

• Allowequipmentto coolbeforetouching.

• Keepatleast5 feet(152cm)of clearanceonall sidesof generatorincludingoverhead.

• Removeshelterwhentemperaturesareabove40°F[4°C].

7. Removeshelter when temperatures are above 40°F [4°C].

8. Turn engine OFFand let cool two (2) minutes before refueling. Let anyspilled fuel evaporatebefore starting engine.

Buildinga ColdWeather Shelter

1. Using noncombustible materialwith a fire rating of at least one hour, build a shelter that will enclose three sides and the top of the generator. Makesure muffler side of generator is exposed.

NOTICE Contactyour local building materialsupplier for non combustible materialswith a fire rating of at least one

hour. NOTICE Besure shelter caneasily be repositioned for

changein wind direction.

2. DONOTenclose generator any more than shown. Sheltershould hold enough heat createdby the generatorto prevent icing problem.

NOTICE If a wheel kit is installed on the generator, enlarge shelter accordingly.

3. Follow steps 3 through 8 asdescribed previously in

Creatinga TemporaryCold WeatherShelter.

A WARNING Runningengine gives off carbon

monoxide, an odorless, colorless, poison gas. Breathingcarbon monoxidecancause headache,

fatigue, dizziness,vomiting, confusion, seizures,

nausea,fainting or death.

• OperategeneratorONLYoutdoors.

• Installa batteryoperatedcarbonmonoxidealarmnearthe bedrooms.

Keepexhaustgas from entering a confined areathrough windows, doors,ventilation intakes, or other openings.

DO NOTstart or run engine indoors or in an enclosedarea, (even if windows anddoors are open), including the generator compartment of arecreational vehicle (RV).

Don't Overload Generator

Capacity

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

1. Selectthe 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 keepyour items running. Seethe table on the right.

3. Estimatehow many surge (starting) watts you will need. Surge wattageis the short burst of power neededto start electric motor-driven tools or appliancessuch as a circular saw or refrigerator. Becausenot all motors start atthe sametime, total surgewatts can be estimatedby adding only the item(s) with the highest additionalsurge watts to the total ratedwattsfrom step2.

Example:

Running(Rated)

Toolor Appliance

Microwave Oven

Refrigerator

FurnaceFan

Light (75 Watts)

Total Rated(Running) Watts = 2575 HighestAdditional SurgeWatts = 2350 Total GeneratorOutput Required =4925

Power Mlanagement To prolong the life of your generatorand attacheddevices, it

is important to take care when adding electrical loadsto your generator. Thereshould be nothing connectedto the generator outlets before starting its engine.Thecorrect and safe way to managegeneratorpower isto sequentially add

loads asfollows:

1. With nothing connectedto the generator,start the engine asdescribed inthis manual.

2. Plug in andturn on the first load, preferablythe largest load you have.

3. Permit the generatoroutput to stabilize (engineruns smoothly and attacheddeviceoperates properly).

4. Plug in andturn on the next load.

5. Again, permit the generatorto stabilize.

6. Repeatsteps 4 and 5 for eachadditional load.

Watts

1000

7OO 8OO

2575 Total

RunningWatts

AdditionalStarting

(Surge) Watts

2200 2350

2350 Highest

Starting Watts

WattageReferenceGuide

Running* Additional

Tool orAppliance (Rated) Starting

Watts (Surge)

Watts

Essentials

Light Bulb - 75 watt 75 -- FurnaceFanBlower- 1/2 HP 800 2350

Sump Pump- 1/3 HP 800 1300 Refrigerator/Freezer 700 2200

Water Well Pump - 1/2 HP 1000 2100

Heating/Cooling

Window AC - 10,000 BTU 1200 3600 Humidifier- 13 Gal 175 --

CentralAC- 24,000 BTU 3800 11400

Kitchen

Microwave Oven- 1000 Watt 1000 -- CoffeeMaker 1000 -- Electric Stove - 8" Element 2100 --

Toaster 850 --

Family Room

DVD/CDPlayer 100 -- VCR 100 --

Stereo Receiver 450 -- Color Television- 27 in 500 --

PersonalComputer w/17 in 800 --

monitor

Other

Security System 500 -- AM/FM Clock Radio 100 --

GarageDoor Opener- 1/2 HP 875 2350 ElectricWater Heater 4700 11700

DIY/JohSite

Quartz HalogenWork Light 1000 -- Airless Sprayer- 1/3 HP 600 1200

Reciprocating Saw 960 -- Electric Drill - 1/2 HP, 5.4 Amps 600 900

Circular Saw - 7-1/4 in 1400 2300 Miter Saw- 10 in 1800 1800

TablePlaner- 6 in 1800 1800 TableSaw/RadialArm Saw - 10 in 2000 2000

Air Compressor - 1 HP 1600 4500

NEVERadd more loads than the generator capacity.Take special careto consider surge loads in generator capacity, as

described above.

* Wattageslisted areapproximate only. Checktool or

appliancefor actualwattage.

16 BRIGGSandSTRATTON.COIVl

Maintenance

MaintenanceSchedule

Follow the hourly or calendarintervals, whichever occurs first. More frequent serviceis required when operating in

adverseconditions noted below.

• Changeengine oil

• Cleandebris

• Checkengineoil level

• Service engineair cleanerpre-filter'

• Changeengine oil'

• Serviceengine air cleanerpaper filter'

• Servicefuel filter

• Servicespark plug

• Inspect muffler and spark arrester

• Cleancooling system'

1 Service more often under dirty or dusty conditions.

GeneralRecommendations

Regular maintenancewill improve the performance and extend the life of the generator.Seeany authorizeddealer for service.

Thegenerator's warranty does not cover items that have been subjectedto operator abuseor negligence.To receive full valuefrom the warranty, the operator must maintain the generator asinstructed in this manual.

Someadjustments will needto be made periodically to properly maintain your generator.

All service and adjustments should be made at least once eachseason.Follow the requirementsin the Maintenance

Schedulechart above. NOTICE Oncea year you should cleanor replacethe spark

plug and replacethe air filter. A new spark plug and clean air filter assure proper fuel-air mixture and help your engine run better and last longer.

EmissionsControl Maintenance, replacement, or repair of the emissions

controldevicesand systemsmay be performedby any non-roadengine repair establishmentor individual.

However,to obtain "no charge" emissions control service, the work must beperformed by a factory authorizeddealer. Seethe Emissions Warranty.

GeneratorMaintenance

Generatormaintenanceconsists of keepingthe unit clean and dry. Operateand store the unit in a clean dry environment where it will not be exposedto excessive dust, dirt, moisture, or any corrosive vapors. Coolingair slots in the generator must not become cloggedwith snow, leaves, or any other foreign material.

NOTICE DO NOTusewater or other liquids to clean generator. Liquids canenter engine fuel system, causing poor performance and/or failure to occur. In addition, if liquid enters generator through cooling air slots, some of the liquid will be retainedin voids and cracks of the rotor and stator winding insulation. Liquid anddirt buildup on the generator internalwindings will eventually decreasethe insulation resistanceof these windings.

Cleaning

Dailyor before use, look around and underneaththe generatorfor signs of oil or fuel leaks. Cleanaccumulated debris from inside and outside the generator. Keepthe linkage, spring and other engine controls clean. Keepthe areaaround andbehind the muffler free from any combustible debris. Inspect cooling air slots and openings on generator. Theseopenings must be kept clean and

unobstructed. Engine parts should be kept cleanto reducethe riskof

overheating and ignition of accumulateddebris:

• Usea damp cloth to wipe exterior surfaces clean.

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

• DO NOTexpose generator to excessivemoisture, dust, dirt, or

corrosive vapors.

• DONOTinsert any objects through cooling slots.

• Usea soft bristle brush to loosen cakedon dirt or oil.

• Usea vacuum cleanerto pick up loose dirt and debris.

FuelValve Maintenance

Thefuel valve is equipped with a fuel sediment cup, screen, retaining ring and o-ring that needto becleanedevery 100 hours or once a year (whichever occurs first).

1. Move fuel valve to "Off" position.

2. Removesediment cup (A) from fuel valve. Remove o-ring (B), retaining ring (C) and screen (D) from fuel

valve.

oF oc

68 _mo >_20

104 n _, __ , !l_'X_ 40

86 _om__ _,_ o__ 30

so 10

32 o ._m -- 0

-2214-4 -- , l--___' -30-20-10

3. Wash sediment cup, o-ring, retaining ring, andscreen in a nonflammable solvent. Drythem thoroughly.

4. Placescreen, retaining ring, and o-ring into fuel valve. Install sedimentcup andtighten securely.

5. Move fuel valve to "On" position, and checkfor leaks. Replaceo-ring if there is any leakage.

EngineMaintenance

_i, WARNING Unintentionalsparking can result in fire or

_ electric shock.

WHENADJUSTINGORMAKINGREPAIRSTOYOUR GENERATOR

• Disconnectthesparkplugwirefromthesparkplugandplace thewirewhereit cannotcontactsparkplug.

WHENTESTINGFORENGINESPARK

• Useapprovedsparkplugtester.

• DONOTcheckfor sparkwith sparkplugremoved.

* Below 40°F ** Above 80°F (27°C) the useof 10W30 may cause increasedoil

consumption. Oheckoil levelmore frequently.

CheckingOil Level

Oil level should be checked prior to each useor at least every 8 hours of operation. Keepoil levelmaintained.

1. Make sure generator is on a level surface.

2. Cleanarea around oil fill, removeoil cap/dipstick and

NOTICE DO NOTscrew in dipstick when checking oil level.

3. Verify oil is at "Full" mark (E) on dipstick. Replaceand

(4°C)theuseofSAE30 will resultin hardstarting.

certification mark and API servicesymbol with

NOTICE Synthetic oil meeting ILSACGF-2,API "SJ/CF ENERGYCONSERVING"or higher, is an

acceptableoil at all temperatures. Useof synthetic oil does not alter required oil change intervals.

wipe dipstick with cleancloth. Replacedipstick. Removeandand check oil level.

tighten oil cap/dipstick.

Oil Recommendations We recommendthe useof Briggs & Stratton Warranty

Certified oils for best performance.Otherhigh-quality detergent oils are acceptableif classified for serviceSF, SG, SH, SJ or higher. DONOTuse specialadditives.

Outdoor temperatures determine the proper oil viscosity for the engine. Usethe chart to select the best viscosity for the outdoor temperature rangeexpected.

18 BRIGGSandSTRATTON.COIVl

AddingEngineOil

1. Make sure generator is on a level surface.

2. Checkoil level as described in CheckingOilLevel

3. If needed,slowly pour oil into oil fill opening to the "Full" mark on dipstick. DONOToverfill.

NOTICE Overfilling with oil may causethe engine to not start, or hard starting.

• DONOToverfill.

• Ifoverthe FULLmarkondipstick,drainoilto reduceoil levelto FULLmarkondipstick.

4. Replaceand tighten oil cap/dipstick.

ChangingEngineOil

If you are usingyour generator under extremely dirty or dusty conditions, or in extremelyhot weather, changethe oil

more often.

& CAUTION Avoid prolonged or repeated skin contact with used motor oil.

• Used motor oil has beenshown to cause skin cancer in certain laboratory animals.

• Thoroughly wash exposed areaswith soap and water.

POLLUTE.CONSERVERESOURCES.RETURN USEDOILTOCOLLECTIONCENTERS.

KEEPOUTOFREACHOFCHILDREN.DON'T

Changethe oil while the engineis still warm from running,as follows:

1. Make sure unit is on a level surface.

2. Disconnectthe spark plug wire from the spark plug and placethe wire where it cannot contact spark plug.

3. Cleanarea around oil drain plug.The oil drain plug is located at base of engine,opposite carburetor.

4. Removeoil drain plug and drain oil completely into a suitable container.

5. Reinstall oil drain plug andtighten securely. Remove oil cap/dipstick.

6. Slowly pour recommendedoil (about 30 oz.) into oil fill opening. Pauseto permit oil to settle. Fill to "Full" mark

on dipstick.

7. Wipe dipstick cleaneachtime oil levelis checked. DO NOToverfill.

8. Reinstall oil cap/dipstick. Tighten cap securely.

9. Wipe up any spilled oil.

ServiceAir Cleaner

Your enginewill not run properly and may be damaged if you run it with a dirty air cleaner.Cleanor replacemore often if operating underdusty or dirty conditions.

To servicethe air cleaner, followthese steps:

1. Loosen screws (A) and removeair cleaner cover (B).

2. Carefully removefoam pre-filter (C) andpaper filter (D).

3. Wipe cleaninside of base(E) and cover thoroughly.

4. Cleanor replacethe foam pre-filter. To clean, wash pre- filter in a solution of householddetergent and warm water, then rinse thoroughly. Squeezedry in aclean

cloth.

5. Saturatefoam pre-filter in cleanengine oil and squeeze in a clean, absorbent cloth to removeall excessoil. DO

NOTtwist.

NOTICE The engine will smoke during initial start-up if too much oil is left inthe pre-filter.

6. Cleanpaperfilter by tapping it gently ona solid surface. If the paperfilter is too dirty, replaceit with a new one. Disposeof the old filter properly.

7. Insert the foam pre-filter into the air cleanercover, then the paper filter.

8. Assembleair cleaner cover onto baseand tighten screws.

Service Spark Plug Changingthe spark plug will helpyour engineto start easier

and run better.

1. Cleanarea around spark plug.

2. Removeand inspect spark plug.

3. Checkelectrode gapwith wire feeler gauge and reset spark plug gap to recommended gapif necessary(see

Specifications).

4. Replacespark plug if electrodesare pitted, burned or porcelain is cracked. Usethe recommended

replacementspark plug. SeeSpecifications.

5. Install spark plug andtighten firmly.

InspectMluffler and Spark Arrester Inspect the muffler for cracks, corrosion, or other damage.

Removethe spark arrester, if equipped, and inspectfor damageor carbon blockage. If replacementparts are required, make sure to use only original equipment replacementparts.

_i, WARNING Contact with muffler area can result in

serious burns. Exhaust heat/gases can ignite

combustibles, structures or damage

fuel tank causing a fire.

• DO NOTtouch hot parts andAVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keepat least5 feet (152 cm) of clearanceon all sidesof generator including overhead.

federal jurisdictions may have similar laws.

Contactthe original equipment manufacturer, retailer, or dealer

to obtain a sparkarrester designed for the exhaust system

installed on this engine.

• Replacement parts must bethe same and installed inthe same position asthe original parts.

Cleanand inspectthesparkarresteras follows:

1. To remove muffler heatshield (A) from muffler (B), removefour screws that connect guard to muffler

bracket.

CleanCoolingSystem Overtime debris may accumulatein cylinder cooling fins and

cannot be observedwithout partial enginedisassembly. For this reason,we recommendyou havea Briggs & Stratton authorized dealerclean the cooling system (D) per recommended intervals (seeMaintenanceScheduleinthe Maintenancesection). Equally important is to keeptop of engine freefrom debris. Also see Cleaning.

CarburetorAdjustment

Thecarburetor on this engine is low emission. It is equipped with a non-adjustable idle mixture valve. Top speed has been set at the factory. If adjustment is required,see a Briggs &

Stratton authorized dealer.

_i, CAUTION Excessively high operating speeds increase

risk of injury and damage to generator.

Excessively low speeds impose a heavy load.

• DO NOTtamper with governedspeed. Generatorsupplies correct rated frequency and voltage when running at governed speed.

• DO NOTmodify generator in any way.

Removefour screwsthat attachsparkarresterscreen(C).

Inspect screenand obtain areplacementif torn, perforated or otherwise damaged. DONOTuse a defective screen.If screenis not damaged,clean it with

commercial solvent.

4. Reattachscreen and muffler guard.

20 BRIGGSandSTRATTON.COIVl

Storage

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

GeneratorStorage

• Cleanthe generator as outlined in Cleaningin the Maintenancesection.

• Checkthat cooling air slots and openingson generator

are open and unobstructed.

LongTerm StorageInstructions

Fuelcan becomestale when stored over 30 days.Stalefuel causesacid and gum deposits to form in the fuel system or on essential carburetor parts. To keepfuel fresh, use Briggs

& Stratton FRESHSTART® fuel stabilizer, availableasa liquid additive or adrip concentratecartridge.

Thereis no needto drain gasolinefrom the engineif a fuel stabilizer is added according to instructions. Runthe engine for 2 minutes to circulate the stabilizerthroughout the fuel system. The engine andfuel canthen be stored up to

24 months. If gasoline in the engine hasnot beentreated with a fuel

stabilizer, it must bedrained into an approvedcontainer. Run the engine until it stops from lack of fuel. The useof a fuel stabilizer in the storage container is recommended to

maintain freshness.

ChangeEngineOil

While engine is still warm, drain oil from crankcase.Refill with recommended grade.See Changing Engine Oil.

OtherStorageTips

1. DONOTstore fuel from one seasonto another unless it has beentreated as described in Protect FuelSystem.

2. Replacefuel can if it starts to rust. Contaminatedfuel will cause engine problems.

3. Cover unit with a suitable protective coverthat does not retain moisture.

_i, WARNING Storagecovers can be flammable.

• DO NOTplace a storage cover overa hot generator.

• Let equipment coolfor a sufficient time before placing the cover on the equipment.

4. Store generator in clean, dry area.

_i, WARNING Fueland its vapors are extremely

flammable and explosive.

_ J

_, _ Fire or explosion can causesevere

burns or death.

WHENSTORINGFUELOREQUIPMENTWITHFUELINTANK

• Store away from furnaces, stoves, water heaters,clothesdryers or other appliances that have pilot light or other ignition source

becausethey can ignite fuel vapors.

WHENDRAININGFUEL

• Turn generator OFFand let itcool at least2 minutes before removing fuel cap. Loosen cap slowly to relievepressure in

tank.

• Drain fuel tank outdoors.

• Keepfuel awayfrom sparks, open flames, pilot lights, heat, and other ignition sources.

• DO NOTlight a cigarette or smoke.

Troubleshooting

Problem

Engineisrunning,but noAC outputis available.

Enginerunsgoodat no-load but "bogs down"when loads

are connected.

Enginewill notstart; or starts and runsrough.

Engineshutsdownwhen running.

Enginelackspower.

Engine"hunts" or falters.

Cause

1. GFCIcircuit breakeris open.

2. Fault in generator.

3. Poor connection or defectivecord set.

4. Connecteddeviceis bad.

1. Short circuit in aconnectedload.

Enginespeed is too slow.

Generatoris overloaded.

Shorted generator circuit.

Cloggedor dirty fuel filter.

Engineswitch setto stop (0) position. 1.

Fuelvalveis in "Off"position. 2.

3. Low oil level.

4. Dirty air cleaner.

5. Cloggedor dirty fuel filter.

6. Out of fuel.

7. Stalefuel.

Spark plug wire not connectedto spark plug.

9. Badspark plug.

10. Water in fuel.

11. Flooded.

12. Excessivelyrich fuel mixture.

13. Intakevalvestuck open or closed.

14. Engine has lost compression.

1. Out of fuel.

2. Cloggedor dirty fuel filter.

3. Low oil level.

1. Loadis too high.

2. Dirty air filter.

3. Cloggedor dirty fuel filter.

1. Carburetoris runningtoo rich or too lean.

2. Cloggedor dirty fuel filter.

Correction

1. Resetcircuit breaker.

2. Contact Briggs & Stratton authorized dealer.

3. Checkand repair.

4. Connectanotherdevice that is in good condition.

1. Disconnectshorted electrical load.

Contact Briggs & Stratton authorized dealer.

SeeDon't OverloadGenerator.

Contact Briggs & Stratton authorized dealer.

Cleanor replacefuel filter. Setswitch to run (I) position.

Turnfuel valveto "On"position.

3. Fillcrankcaseto proper levelor place generatoron level surface.

4. Cleanor replaceair cleaner.

5. Cleanor replacefuel filter.

6. Fillfuel tank.

7. Drainfuel tank and carburetor; fill with fresh fuel.

8. Connectwire to spark plug.

9. Replacespark plug.

10. Drainfuel tank and carburetor; fill with fresh fuel.

11. Wait 5 minutes and re-crank engine.

12. Contact Briggs & Stratton authorized dealer.

13. Contact Briggs & Stratton authorized dealer.

14. Contact Briggs & Stratton authorized dealer.

1. Fillfuel tank.

2. Cleanor replacefuel filter.

3. Fillcrankcaseto proper levelor place generatoron level surface.

1. SeeDon't OverloadGenerator.

2. Replaceair filter.

3. Cleanor replacefuel filter.

1. Contact Briggs & Stratton authorized dealer.

2. Cleanor replacefuel filter.

22 BRIGGSandSTRATTON.COIVl

Schematic

55A

BATTERY CHARGE

PI-6 12V DC

CB2

13 _ 13A

loA

IDLE CONTROL

CIRCUIT BOARD ==

IDLE

CONTROL

COIL

HQURMETER

12VDC

155

156

LiB oi_o_____

IDLE

CONTROL

SWITCH

22 J 022 VOLTAGE J

i oli i

BLA_ _ REGULATOR (_ I WH__.ITE

/'PI-2

_TB-3

I 20A

I 2P

GFCI '

m m i

L ....

POWER

\ \

PI-5

POWER

155 156

t PI-4

.... l

I i I I i

m i

IIA

120V

30A

WHITE_

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24 BRIGGSandSTRATTON.COIVl

Warranties

California,U.S. EPA,andBriggs& Stratton CorporationEmissionsControlWarranty

Statement

YourWarranty RightsAndObligations

The CaliforniaAir ResourcesBoard,U.S. EPA,and Briggs & Stratton (B&S) are pleasedto explainthe emissions control system warranty on your ModelYear2008 andlater engine/equipment. In California,new small off-road engines must be designed, built, and equipped to meetthe State's stringent anti-smog standards. B&Smust warrant the emissions control system on your engine/equipmentfor the periods of time listed below provided there has been no abuse, neglect,or improper maintenanceof your small off- road engine.

Your emissions control system may include partssuch as the carburetor or fuel injection system, fuel tank, ignition system, and catalytic converter. Also included may behoses,

belts, connectors, sensors, andother emissions-related assemblies.Wherea warrantable condition exists, B&S will

repair your engine/equipmentat no cost to you including diagnosis, parts, and labor.

Manufacturer'sWarrantyCoverage:

Small off-road engines arewarranted for two years. If any emissions-related part on your engine/equipment is

defective,the part will be repaired or replacedby B&S. Owner's WarrantyResponsibilities:

• As the small engine/equipment owner, you are responsiblefor the performance of the required

maintenancelisted in your owner's manual. B&S

recommendsthat you retainall receipts covering

maintenanceonyour engine/equipment, but B&S cannot deny warranty solely for the lack of receiptsor

your failure to ensurethe performanceof all scheduled maintenance.

• As the engine/equipmentowner,you should however

be awarethat B&Smay deny you warranty coverageif your engine/equipmentor a part hasfailed due to abuse, neglect,improper maintenance,or unapproved

modifications.

• Youare responsiblefor presentingyour

engine/equipmentto a B&Sdistribution center, servicing dealer,or other equivalententity, as

applicable, assoon as a problem exists. Thewarranty

repairsshould be completed in a reasonableamount of

time, not to exceed30 days. If you haveany questions

regardingyour warranty rights andresponsibilities, you

should contact B&Sat (414) 259-5262.

Briggs& Stratton EmissionsControlWarrantyProvisions Thefollowing are specific provisions relativeto your

Emissions Control Warranty Coverage.It is in addition to the

B&S enginewarranty for non-regulatedengines found in the

Operator's Manual.

1. Warranted Emissions Parts Coverageunder this warranty extends only to the parts

listed below (the emissions control systems parts) to the extentthese parts were present on the engine purchased.

a. FuelMetering System

• Cold start enrichment system (soft choke)

• Carburetorand internal parts

• Fuelpump

• Fuelline, fuel line fittings, clamps

• Fueltank, capand tether

• Carboncanister

b. Air Induction System

• Air cleaner

• Intake manifold

• Purgeand vent line

Ignition System

• Spark plug(s)

• Magnetoignition system

CatalystSystem

• Catalyticconverter

• Exhaustmanifold

• Air injection system or pulse valve

e. Miscellaneous Items Used in Above Systems

• Vacuum,temperature, position, time sensitive valvesandswitches

• Connectorsand assemblies

Length of Coverage For a period of two yearsfrom date of original purchase, B&S warrants to the original purchaser and eachsubsequent purchaserthat the engine is designed, built, and equippedso as to conform with all applicable regulations adopted by the Air Resources Board; that it is free from defectsin materialand workmanship that could cause the failure of a warranted part; and that it is identical in all material respects to the engine described in the manufacturer's application for certification. The warranty period beginson the datethe engine is originally purchased.

Thewarranty on emissions-related parts is asfollows:

• Anywarranted part that is not scheduledfor replacementas required maintenancein the owner's

manual supplied, is warranted for the warranty period stated above. If any such part fails during the period of warranty coverage,the part will be repairedor replaced by B&S at no chargeto the owner. Any such part

repairedor replacedunder the warranty will be

warranted for the remaining warranty period.

• Anywarranted part that is scheduled only for regular

inspection in the owner's manual supplied, is warranted for the warranty period statedabove. Any such part

repairedor replacedunder warranty will be warranted

for the remaining warranty period.

• Anywarranted partthat is scheduledfor replacementas requiredmaintenancein theowner's manualsupplied, is

warrantedfor the period of time prior to the first scheduledreplacementpointfor that part. If the part fails prior to thefirst scheduled replacement,the part will be

repairedor replacedby B&S at no charge to the owner.

Anysuch part repairedor replacedunderwarrantywill be warrantedfor the remainder of the period prior to the first scheduledreplacementpointfor the part.

• Addon or modified parts that are not exempted by the

Air Resources Board may not be used.The useof any non exempted add on or modified parts by the owner will be grounds for disallowing a warranty claim. The

manufacturer will not be liable to warrantfailures of warranted parts causedbythe useof a non exempted

add on or modified part.

3. ConsequentialCoverage Coverageshall extend to the failure of anyengine

components causedby the failure of anywarranted emissions parts.

4. Claimsand CoverageExclusions Warranty claims shall be filed according to the

provisions of the B&S enginewarranty policy. Warranty coveragedoes not apply to failures of emissions parts that are not original equipment B&S partsor to parts that fail due to abuse, neglect, or improper maintenance as set forth in the B&S engine warranty policy. B&Sis not liable for warranty coverageof failures of emissions parts causedby the useof add-on or modified parts.

LookFor RelevantEmissionsDurability Period andAir IndexInformationOnYour EngineEmissionsLabel

Enginesthatare certified to meetthe CaliforniaAir

ResourcesBoard (CARD)Emissions Standardmust display information regardingthe Emissions Durability Period and the Air Index. Briggs & Stratton makesthis information

availableto the consumer on our emissions labels. The engine emissions labelwill indicate certification information.

TheEmissionsDurabilityPerioddescribesthe number of hours of actual runningtime for which the engine is certified to be emissions compliant, assuming proper maintenancein accordancewith the Operating& Maintenance Instructions. Thefollowing categoriesare used:

Moderate:

Engine is certified to be emissions compliant for 125 hours of actual enginerunning time.

Intermediate:

Engine is certified to be emissions compliant for 250 hours of actual enginerunning time.

Extended:

Engine is certified to be emissions compliant for 500 hours of actual enginerunning time.

Forexample,a typical walk-behind lawn mower is used 20 to 25 hours peryear. Therefore,the Emissions Durability Period of anengine with an intermediate rating would equateto 10to 12 years. Briggs & Stratton enginesare

certified to meet the United States EnvironmentalProtection Agency (USEPA)Phase2 emissions standards.For Phase2

certified engines, the Emissions CompliancePeriod referred to on the EmissionsCompliancelabel indicatesthe number of operating hours for which the engine has beenshown to meet Federalemissions requirements.

Forengines less than 225 cc displacement. CategoryC= 125 hours CategoryB= 250 hours CategoryA= 500 hours

Forengines of 225 cc or more displacement. CategoryC= 250 hours CategoryB= 500 hours CategoryA= 1000 hours

26 BRIGGSandSTRATTON.COM

+ 58 hidden pages

Briggs & Stratton PRO400, PRO4000 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual