Briggs & Stratton PRO6500 User Manual

Manual No. 195994GS

Revision 0 (10/06/2004)

Model / Modèle / Modelo

PRO6500

01933

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

Owner’s Manual

Questions? Help is just a

moment away!

Call: Generator Helpline -

1-800-743-4115 M-F 8-5 CT

Manuel de l'utilisateur

Vous avez des questions?

Vous n'avez pas besoin d'aller loin

pour trouver de l'aide!

Appelez: Ligne d'assistance de Générateur - 1-800-743-4115

M-F 8-5 CT

Manual del Propietario

Preguntas? La ayuda es justa un

momento lejos!

Llamada: Generador Helpline -

1-800-743-4115 M-F 8-5 CT

BSPP Generator

TABLE OF CONTENTS

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

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

EQUIPMENT

DESCRIPTION

Read this manual carefully and become familiar with your generator. Know its applications, its limitations and any hazards involved.

This generator is an engine–driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliances, tools and motor loads.The generator’s revolving field is driven at about 3,600 rpm by the engine.

This generator incorporates GFCI (Ground Fault Circuit Interrupter) outlet protection and has its neutral bonded to ground to pass OSHA inspections on job sites.This generator will not function when connected to a transfer switch since the home or building main breaker box also has a neutral bonded to ground.When both the generator and the home or building breaker box contains a neutral bonded to ground, the generators GFCI will open and no outlets will function.

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

• Removing the neutral bond could result in death, bodily injury and/or property damage.

DO NOT remove the neutral bond.

WARNING

Fire

Explosion

Toxic Fumes

Kickback

Electrical Shock

Electrocution

Electrical Shock

Explosive Pressure

Chemical Burn

Hot Surface

BSPP Generator

• 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

• 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

• DO NOT allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas during recharging.

Hydrogen gas stays near battery for a long time after battery has been charged.

Slightest spark will ignite hydrogen and cause explosion.

You can be blinded or severely injured. Battery electrolyte fluid contains acid and is

extremely caustic. Contact with battery fluid will cause severe

chemical burns.

DANGER

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

• DO NOT operate generator inside any building or enclosure, 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 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

BSPP 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.

• The generator must be at least 5 feet from structures having combustible walls and/or other combustible materials.

• Keep at least 3 feet of clearance on all sides of generator for adequate cooling, maintenance and servicing.

• 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,

etc. can catch fire.

WARNING

• When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in and turned on.

Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises or sprains could result.

WARNING

BSPP Generator

KNOW YOUR GENERATOR

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

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

12 Volt DC Receptacle — Use this receptacle with battery charge cables to charge a 12 Volt battery.

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

120 Volt AC, 30 Amp Locking Receptacle — May be used to supply electrical power for the operation of 120Volt AC, 30 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 if calling for assistance.

Fuel Tank — Capacity of seven (7) U.S. gallons. GFCI Circuit Breaker — A GFCI circuit breaker is provided to

protect against electrical ground fault and protect the generator against electrical overload.

Grounding Fastener — If required, please consult a qualified electrician, electrical inspector, or local agency having jurisdiction.

Hour Meter — Displays and records how many hours your generator has run (up to 9,999.9).

Idle Control Switch — The idle control runs the engine at normal (high) speeds when there is a load present and runs the engine at idle (low) speeds when a load is not present.

Oil Fill Cap — Add oil to engine here. Spark Arrester Muffler — Exhaust muffler lowers engine noise

and is equipped with a spark arrester screen.

Choke Lever

120 Volt AC , 20 Amp Duplex Receptacle

12 Volt DC Receptacle

Spark Arrester Muffler

Grounding Fastener

Air Cleaner

Fuel Tank

Oil Fill Cap

Data Tag

Hour Meter

Idle Control Switch

GFCI Circuit Breaker

120/240 Volt AC, 30 Amp Locking Receptacle

120 Volt AC, 30 Amp Locking Receptacle

Circuit Breakers

BSPP 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.

Remove Generator From Carton

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

2. Carefully open top flaps of 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 generator from shipping carton.

Carton Contents

Check all contents. If any parts are missing or damaged, call the generator helpline at 1–800–743–4115.

• The generator

• Generator owner’s manuals

• Engine owner’s manuals

• (2) Locking 30A plugs

• Battery charge cables

• Engine oil

• Wheel kit

Install Wheel Kit

The wheel kit is designed to greatly improve the portability of your generator.

NOTE:Wheel kit is not intended for over-the-road use. You will need a 1/2" or 13mm socket wrench and a 1/2" or

13mm open end wrench and a 7/16" socket wrench and 7/16" open end wrench and a needle-nose pliers to install this kit.

NOTE:Adjustable wrenches may be substituted for open end wrenches.

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.

Support Leg

Nut

Axle

Flat Washer

Wheel

E-Ring

Figure 1 — Install Wheel Kit

20 mm Cap Screw

Nut

3/4” Cap Screw

Vibration Mount

Use existing hardware to attach left side of support leg to unit

Nut

Handle Pin

Handle

Flat Washer

Nylon Washer

45 mm Cap Screw

Nylon Washer

Your unit may vary slightly from that shown here

BSPP Generator

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 both wheels with the air pressure valve on the outboard side.

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

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 the vibration mounts to the support leg with 1/4-20 x 3/4” capscrews and 1/4-20 lock nuts.

9. To aid support leg assembly, rest generator on cradle, engine end down. Remove the existing hardware from the left unit vibration mount with 13mm wrench. Use the same hardware to attach the support leg.

10. Attach the other side of the support leg with a M8 x 20 mm cap screw and M8 lock nut. Rest generator on wheels and support leg.

11. Attach handles to handle brackets on generator frame, as shown in Figure 1, with M8 x 45 mm capscrews, flat washers, nylon washers,and M8 lock nuts.

NOTE: Be sure to install the nylon washers between the handle brackets on the generator frame and the brackets on the handle assembly.

12. Loop handle pins to generator frame as shown in Figure 1. Raise handles and insert handle pins to move generator.

13. Check each fastener to ensure it is secure and the tires are inflated between 15-40 PSI.

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 with equipment. 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 fill above the baffle.This allows adequate 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

Figure 2 — Typical Fuel Expansion Space

Baffle

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 (see “Equipment Description”, earlier in this manual).

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.

Generator Location

Generator Clearance

The generator must be at least 5 ft. (152 cm) from structures having combustible walls and/or other combustible materials. Leave at least 3 ft. (92 cm) all around generator including overhead, for adequate cooling, maintenance and servicing.

Place generator in a well ventilated area, which will allow for removal of deadly exhaust gas. DO NOT place generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building. Ensure exhaust gas is kept away from any windows, doors, ventilation intakes or other openings that can allow exhaust gas to collect in a confined area (Figure 3). Prevailing winds and air currents should be taken into consideration when positioning generator.

• 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

BSPP Generator

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

• DO NOT operate generator inside any building or enclosure, 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

Figure 3 — Generator Clearance

Exhaust Port

Typical Generator Shown

OPERATING THE

GENERATOR

Starting the Engine

Disconnect all electrical loads from the generator. Use the following start instruction steps in numerical order:

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 fuel valve to “On” position (Figure 4).

3. Make sure Idle Control switch is in “Off” position

(Figure 5).

4. Follow start instructions given in engine owner’s manual. 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. Move idle control switch to “Off” position.

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

stabilize internal temperatures of engine and generator.

4. Move fuel valve to “Off” position.

5. Turn engine off according to instructions given in the

engine owner’s manual.

BSPP Generator

Figure 4 — Fuel Shut-off 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

Figure 5 — Idle Control Switch

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

• The generator must be at least 5 feet from structures having combustible walls and/or other combustible materials.

• Keep at least 3 feet of clearance on all sides of generator for adequate cooling, maintenance and servicing.

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,

etc. can catch fire.

WARNING

Operating Automatic Idle Control

This switch is designed to greatly improve fuel economy. When this switch is turned ON, the engine will only run at its normal high governed engine speed when electrical loads are connected.When an electrical load is removed, the engine will run at a reduced speed.

With the switch off, the engine will run at the normal high engine speed. Always have the switch off when

starting and stopping the engine.

Charging a Battery

Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage battery. DO NOT use the unit to charge any 6 Volt batteries. DO NOT use the unit to crank an engine having a discharged battery.

To recharge 12 Volt batteries, proceed as follows:

1. Check fluid level in all battery cells. If necessary, add ONLY distilled water to cover separators in battery cells. DO NOT use tap water.

2. If battery is equipped with vent caps, make sure they are installed and are tight.

3. If necessary, clean battery terminals.

4. Connect battery charge cable connector plug to panel receptacle identified by the words “12-VOLTS D.C.”.

5. Move idle control switch to “Off” position.

6. Connect battery charge cable clamp with red handle to the positive (+) battery terminal (Figure 6).

7. Connect battery charge cable clamp with black handle to the negative (–) battery terminal (Figure 6).

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

9. When battery has charged, shut down engine

NOTE:Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturer’s instructions carefully. Generally,a battery is considered to be at 100% state of charge when specific gravity of its fluid (as measured by hydrometer) is 1.260 or higher.

COLD WEATHER

OPERATION

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

1. Make sure generator has clean, fresh fuel.

2. Open fuel valve (turn valve to open position).

3. Use SAE 5W-30 oil (synthetic preferred, see engine manual).

4. Check oil level daily or after every eight (8) hours of operation.

5. Maintain generator following “Maintenance Schedule” in engine manual.

6. Shelter unit from elements.

BSPP Generator

• DO NOT allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas during recharging.

Hydrogen gas stays near battery for a long time after battery has been charged.

Slightest spark will ignite hydrogen and cause explosion.

You can be blinded or severely injured. Battery electrolyte fluid contains acid and is

extremely caustic. Contact with battery fluid will cause severe

chemical burns.

DANGER

Figure 6 — Battery Connections

BSPP Generator

In an emergency, use the original shipping carton as a temporary shelter:

7. Cut off all carton flaps.

8. Cut out one long side of carton to expose muffler side of unit as shown in Figure 7.

IMPORTANT: The generator must be at least 5 ft. (152 cm) from structures having combustible walls and/or other combustible materials. Leave at least 3 ft. (92 cm) all around generator including overhead, for adequate cooling, maintenance and servicing.

9. Cut appropriate slots to access receptacles of unit.

10. Start unit, then place carton over it.

NOTE: Remove shelter when temperatures are above 40°F [4°C].

For a more permanent shelter, build a structure that will enclose three sides and the top of the generator.

7. Make sure entire muffler-side of generator is exposed, as shown in Figure 7.

8. Face exposed end away from wind and elements.

9. Structure should hold enough heat created by the generator to prevent icing problem.

10. Start and run engine outdoors.

11. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

12. DO NOT enclose generator any more than shown in Figure 7.

13. Remove shelter when temperatures are above 40°F [4°C].

14. Turn engine OFF and let cool two (2) minutes before refueling.

Figure 7 — Permanent Cold Weather Shelter

Wind

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

• The generator must be at least 5 feet from structures having combustible walls and/or other combustible materials.

• Keep at least 3 feet of clearance on all sides of generator for adequate cooling, maintenance and servicing.

• Remove shelter when temperatures are above 40°F [4°C].

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,

etc. can catch fire.

WARNING

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

• DO NOT operate generator inside any building or enclosure, 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

BSPP Generator

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 8).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 6,500 watts of power (6.5 kW) at 27.1 Amps for 120 Volts or 240 Volts.The outlet is protected against overload by a 2 pole GFCI circuit breaker.

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire cord set rated for 125 Volts AC at 30 Amps to the plug (Figure 9).

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3,600 watts (3.6 kW) of power at 30 Amps.The outlet is protected against overload by a 2 pole GFCI circuit breaker.

• 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 8 — 120/240 Volt AC,30 Amp Receptacle

4-Wire Cord Set

240V

120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground (Green)

Figure 9 — 120 Volt AC,30 Amp, Locking Receptacle

3-Wire Cord Set

Neutral

120V

Hot

Ground (Green)

NEMA L5-30

BSPP Generator

120 Volt AC, 20 Amp, Duplex

Receptacle

Each duplex receptacle (Figure 10) is protected against overload by a 2 pole GFCI 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).

12 Volt DC, 10 Amp Receptacle

This receptacle (Figure 11) allows you to recharge a 12 Volt automotive or utility style storage battery.

This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery. See “Charging a Battery” on page 10 before attempting to recharge a battery.This outlet is protected by a 10 Amp self resetting circuit breaker.

Figure 11 — 12 Volt DC,10 Amp Receptacle

Figure 10 — 120 Volt AC, 20 Amp, Duplex Receptacle

Ground Fault Protection

This unit is equipped with a Ground Fault Circuit Interrupter (GFCI).This device meets applicable federal, state and local codes.

The GFCI protects against electrical shock that may be caused if your body becomes a path which electricity travels to reach ground.This could happen if you touch a “Live” appliance or wire, or are touching plumbing or other materials that connect to the ground.

When protected by a GFCI, one may still feel a shock, but the GFCI should cut current off quickly enough so that a person in normal health should not suffer any serious electrical injury.

Test GFCI Circuit Breaker

Test your GFCI circuit breaker (Figure 12) every month, as follows:

1. While generator is running, push white “Test” button.

The circuit breaker should trip (handle will move to approximate center position), which will disconnect power to outlets.

2. If handle moves to center, reset circuit breaker by

firmly moving handle to “Off” (down) position, then to “On” (up) position.

During Generator Use

If circuit breaker trips during use, it usually indicates faulty electrical equipment or cords. However, test the circuit breaker as follows;

1. Disconnect loads, reset and test circuit breaker as described earlier. Let generator run without any loads for 1 minute.

2. If circuit breaker tests correctly, the electrical equipment or extension cords may be faulty. Replace faulty electrical equipment and cords before further use.

BSPP Generator

• 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 or electrical loads.

Generator produces powerful voltage.

DANGER

• The GFCI will not protect you against the following situations:

-Line-to-line shocks;

-Current overloads or line-to-line short circuits.

• The fuse or circuit breaker at the control panel must provide such protection.

Generator produces powerful voltage.

DANGER

• DO NOT use generator.

• Call a Briggs & Stratton Power Products service center.

If circuit breaker does not trip:

CAUTION

Figure 12 — GFCI Circuit Breaker

• DO NOT use generator.

• Call a Briggs & Stratton Power Products service center.

If circuit breaker does not reset properly:

CAUTION

• DO NOT use generator.

• Call a Briggs & Stratton Power Products service center.

If circuit breaker trips in the 1 minute period:

CAUTION

• Have qualified personnel check all electrical equipment and cords for any defects.

• Replace electrical equipment and cords or take to a qualified repair center.

If circuit breaker tests correctly:

CAUTION

BSPP 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 13.

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 75 Deep Freezer 500 500 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 960 960 Electric Drill - 1/2 HP 1000 1000 Circular Saw - 7 1/4” 1500 1500 Miter Saw - 10” 1800 1800 Table Planer - 6” 1800 1800 Table Saw/Radial Arm Saw - 10” 2000 2000 Air Compressor - 1-1/2 HP 2500 2500

Figure 13 - Wattage Reference Chart

SPECIFICATIONS

Maximum Surge Watts . . . . . . . . . . . . . . . . . . . .8,125 watts

Continuous Wattage Capacity . . . . . . . . . . . . . . .6,500 watts

Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0

Rated Maximum Continuous AC Load Current:

At 120 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . .54.2 Amps

At 240 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . .27.1 Amps

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase

Rated Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Hertz

Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . .7 U.S. gallons

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 lbs.

GENERAL MAINTENANCE

RECOMMENDATIONS

The Owner/Operator is responsible for making sure that all periodic maintenance tasks are completed on a timely basis; that all discrepancies are corrected; and that the unit is kept clean and properly stored. NEVER operate a

damaged or defective generator.

Engine Maintenance

See engine owner’s manual for instructions.

KEEP OUT OF REACH OF CHILDREN. DON'T POLLUTE. CONSERVE RESOURCES. RETURN USED OIL TO COLLECTION CENTERS.

Generator Maintenance

Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture or any corrosive vapors. Cooling air slots in the generator must not become clogged with snow, leaves or any other foreign material.

NOTE: DO NOT use a garden hose to clean generator. Water can enter engine fuel system and cause problems. In addition, if water enters generator through cooling air slots, some of the water will be retained in voids and cracks of the rotor and stator winding insulation.Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

Fuel Valve Maintenance

The fuel valve is equipped with a fuel sediment cup, screen, retaining ring and o-ring that need to be cleaned every 6 months or 100 hours (whichever occurs first).

1. Move fuel valve to “Off” position.

2. Remove sediment cup from fuel valve. Remove o-ring, retaining ring and screen from fuel valve (Figure 14).

3. Wash sediment cup, o-ring, retaining ring, and screen in a nonflammable solvent. Dry them thoroughly.

BSPP Generator

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

• Thoroughly wash exposed areas with soap and water.

Avoid prolonged or repeated skin contact with used motor oil.

CAUTION

Figure 14 — Fuel Valve Maintenance

Sediment Cup

O-ring

Retaining Ring

Screen

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

BSPP Generator

4. Place screen, retaining ring, and o-ring into fuel valve. Install sediment cup and tighten securely.

5. Move fuel valve to “On” position, and check for leaks. Replace o-ring if there is any leakage.

Generator Cleaning

• Use a damp cloth to wipe exterior surfaces clean.

• Use a soft bristle brush to loosen caked on dirt or oil.

• Use a vacuum cleaner to pick up loose dirt and debris.

• Use low pressure air (not to exceed 25 psi) to blow

away dirt. Inspect cooling air slots and opening on generator.These openings must be kept clean and unobstructed.

STORAGE

The generator should be started at least once 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.

Generator Storage

• Clean the generator as outlined in “Generator Cleaning”.

• Check that cooling air slots and openings on generator are open and unobstructed.

Engine Storage

See engine owner’s manual for instructions.

Other Storage Tips

• To prevent gum from forming in fuel system or on essential carburetor parts, add fuel stabilizer into fuel tank and fill with fresh fuel. Run the unit for several minutes to circulate the additive through the carburetor. The unit and fuel can then be stored for up to 24 months. Fuel stabilizer can be purchased locally.

• DO NOT store fuel from one season to another unless it has been treated as described above.

• Replace fuel container if it starts to rust. Rust and/or dirt in fuel can cause problems if it's used with this unit.

• Store unit in a clean and dry area.

• DO NOT place a storage cover over a hot generator.

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

Storage covers can be flammable.

WARNING

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

• DO NOT insert any objects through cooling slots.

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

CAUTION

+ 39 hidden pages