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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
Can be used to power individual appliances plugged directly into the generator's outlets, or as a back-up
connection to a building's power supply (via a professionally installed UL-approved transfer switch).
READ and UNDERSTAND this manual completely before using the generator! Failure to properly set up,
operate, and maintain this generator could result in serious injury or death from carbon monoxide poisoning,
electric shock, fire/explosion, or burns. In particular, be aware of the following hazards:
Generators give off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.
ONLY run generator OUTDOORS and at least 20 feet from the home, away from windows, vents and air intakes, to
allow proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to
fresh air RIGHT AWAY. NEVER run generator inside any enclosed or semi-enclosed spaces, including homes,
basements, garages, sheds, boxes, RVs, boats or pick-up truck beds. These spaces can trap poisonous gases, EVEN if
you run a fan or open windows.
Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).
High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly
grounded. Use only UL-listed, outdoor-rated grounded extension cords of proper size.
NEVER plug the generator directly into a wall outlet. ANY connection to a building's electrical system MUST
ISOLATE THE GENERATOR FROM UTILITY POWER via a UL-approved transfer switch installed by a licensed
electrician. Otherwise, back feed from the generator into the power grid could kill utility workers.
DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so
engine does not overheat. Exhaust can be extremely hot. Keep muffler at least 7 feet from all combustible objects.
All fuels are flammable. Never fuel a running or hot engine. Never pump fuel directly into generator at gas station – use
approved container to transfer fuel. Ensure there are no fuel leaks, and keep sources of sparks and flames away.
ALWAYS keep a fire extinguisher rated "ABC" nearby.
CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the "Power load Planning & Management" section
of this manual to determine your power load requirements and then compare to the generator's rated capacity.
INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the "Unpacking
& Delivery Inspection" section for instructions on whom to contact to report missing or damaged parts.
ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to
your building's electrical system. See the "Installation/Initial Set-Up" section for more information about this
requirement.
Any Questions, Comments, Problems, or Parts Orders
Owner's Manual
WARNING
CO Poisoning
Electric shock / Electrocution
Fire / Explosion
Call BRAVE Product Support 1-800-350-8739
MBRPG5500B.2
Item Number: BRPG5500, BRPG8000,
BRPG8000ES, BRPG13000ES
Serial Number: _____________
STOP!
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Summary of Contents for Brave MBRPG5500B.2
- Page 1 ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to your building’s electrical system. See the “Installation/Initial Set-Up” section for more information about this requirement. Any Questions, Comments, Problems, or Parts Orders Call BRAVE Product Support 1-800-350-8739...
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Page 2: Hazard Signal Word Definitions
Hazard Signal Word Definitions... -
Page 3: Table Of Contents
Table of Contents Hazard Signal Word Definitions ....................2 About Your Generator ........................4 Specifications ........................... 6 Safety Label Locations ........................7 Machine Component Identification ....................8 Power Load Planning & Management ..................12 Installation / Initial Set-Up: 1. Unpacking & Delivery Inspection ..................15 2. -
Page 4: About Your Generator
This generator is too heavy for one person to lift without mechanical assistance. An optional wheel kit is available from BRAVE and is recommended if you will be moving the generator unassisted. Contact BRAVE Product Support at 1-800-350-8739 with questions about optional accessories or to order. - Page 5 About Your Generator BRAVE is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user shall assume liability for any modification and/or alterations of this equipment from original design and manufacture.
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Page 6: Specifications
(L x W x H) 7.69” x 5.13” x 7” Battery Dimensions Spark Arrestor Included on muffler Included in manual bag Dimensions 32.38” Length 27” 21.25” 24.38” Width 26.90” Height 22.63” Dry Weight 206 lb. 313 lb. Any Questions, Comments, Problems, or Parts Orders Call BRAVE Product Support 1-800-350-8739... -
Page 7: Safety Label Locations
Burn Hazard good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result. 785265 Danger Warning To order replacement safety labels, call BRAVE 786837 Over Fill Warning Product Support at 1-800-350-8739. 782397... -
Page 8: Machine Component Identification
Machine Component Identification Items: BRPG5500, BRPG8000, BRPG8000ES Ref. Description Ref. Description Recoil Generator Head Fuel Valve Lever 6.5 Gallon Gas Tank Engine Key Switch (BRPG8000ES only) Muffler Vibration Isolation Mount Gasoline Tank Cap Oil Drain Plug Carbon Canister Oil Fill Port Air Cleaner Battery (not included, BRPG8000ES only) Choke Lever... - Page 9 Machine Component Identification Items: BRPG5500, BRPG8000, BRPG8000ES REFERENCE GUIDE Reference 1 – Recoil Grasp firmly when starting engine. Reference 2 – Fuel Valve Lever The Honda engine has an ON-OFF valve. Always keep this valve closed when the generator is not in use.
- Page 10 Machine Component Identification Items: BRPG13000ES Ref. Description Ref. Description Air Cleaner Battery (not included) 11 Gallon Gas Tank Control Panel Gasoline Tank Cap Vibration Isolation Mount Choke Generator Head Engine Key Switch Carbon Canister Oil Drain Plug Fuel Valve Lever Oil Fill Port Muffler...
- Page 11 Machine Component Identification Items: BRPG13000ES REFERENCE GUIDE Reference 1 – Air Cleaner Refer to your Honda engine manual for air cleaner care. Reference 2 – 11 Gallon Gas Tank Large tank allows for extended run capabilities. Always allow room for gasoline expansion by not filling the gas tank completely full.
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Page 12: Power Load Planning & Management
Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. - Page 13 Power Load Planning & Management (cont’d) Running Watts Starting Watts Device (Continuous) (Surge) Clothes Dryer (gas) 1200 Clothes Washer 1150 2300 Coffee Maker 1750 Deep Freezer 1000 Desktop Computer w/ 17" monitor Dishwasher (Hot Dry) 1500 1500 Drill: 1/2in., 5.4 Amps Drill: 3/8in., 4 Amps DVD/CD Player Electric Fence: 25 Miles...
- Page 14 Power Load Planning & Management (cont’d) To calculate the running and starting wattage requirements for the devices you will be powering, follow these steps: 1. Make a list of all electrical devices you will be powering at the same time with the generator. 2.
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Page 15: Installation / Initial Set-Up
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: Steps for Installation / Initial Set-Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity. -
Page 16: Set-Up Either As A Building Back-Up Or Portable Power Source
Installation / Initial Set-Up 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to its rated amount of electrical power. It can supply electricity in two ways: 1. As a back-up, standby power source for a building. For this application, you must arrange for a licensed electrician to connect the generator to your building’s electrical system via the installation of an UL-approved transfer switch. - Page 17 Installation / Initial Set-Up The generator may not power your entire home -- you must work with the installing electrician to determine which devices/appliances you wish to power during an outage. The electrician can help you determine which circuits and devices can be powered simultaneously without overloading the generator.
- Page 18 Installation / Initial Set-Up Item # BRPG8000ES Item # BRPG13000ES 1. Make sure you plug each electrical device/appliance into the correct generator outlet based on the device’s plug configuration and voltage/amperage rating. Never exceed the amperage rating of an outlet. 2.
- Page 19 Use of damaged electric cords can cause electric shock or fire. Note: If an extension cord becomes hot to the touch, it is overloaded or damaged and must be replaced. BRAVE is NOT responsible for damage or injury resulting from customer use of inadequate extension cords.
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Page 20: Selecting A Suitable Site
Installation / Initial Set-Up 4. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation. This location should meet all of the criteria listed below. WARNING: You must choose a suitable site for operating your generator to avoid equipment damage and/or injury and possible death from carbon monoxide poisoning, electric shock, or fire. - Page 21 Installation / Initial Set-Up Adequate cooling The generator needs adequate, unobstructed flow of air to allow for ventilation proper cooling of engine and generator head. WARNING: Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures. ...
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Page 22: Grounding The Generator
Installation / Initial Set-Up Hearing Generators can produce noise levels of up to 95 dB in close proximity, protection which can be dangerous to human hearing with prolonged exposure. Hearing protection may be required for persons working within 15-20 feet of the running generator for an extended period of time. -
Page 23: Battery Installation
Installation / Initial Set-Up 6. Battery Installation Your generator’s engine may be equipped with an electric starter, which requires the installation of a battery (see Specifications section of manual). The battery is to be supplied by the customer and should be installed with the battery securing brackets located near the engine. -
Page 24: Operation
Operation Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessary for safe, successful operation of your generator. Operation Procedures 1. General Safety Rules for Operation 2. Preparing for Operation 3. - Page 25 Operation Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o Excessive change in engine speed, slow or fast o Overheating in load connecting devices o Sparking or arcs from generator o Loss of electrical output o Receptacle damage o Engine misfire...
- Page 26 Operation Static electricity and filling the gasoline tank: Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing gasoline, and from persons carrying a static electric charge Static electricity can explosively ignite gasoline vapors that are present during the fueling process, resulting in serious burns to nearby persons.
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Page 27: Preparing For Operation
Operation 2. Preparing for Operation Position Position generator in accordance with the instructions given in “Installation Initial Set-up, Step 4: Select a Suitable Site” generator & of this manual. Operate outside only, on dry, level ground with at least 20 feet from the home, away from windows, vents and air intakes, to allow proper ventilation. - Page 28 Operation WARNING: Gasoline fire/explosion hazard Gasoline is highly flammable and explosive. Heat, sparks, and flames can ignite gasoline vapors, which can become widespread during fueling. A flash fire and/or explosion could result and cause serious injury or death. Use extreme care when handling gasoline. Carefully follow all the instructions in this section to avoid the following conditions which could result in gasoline ignition: ...
- Page 29 Operation Never fill the portable gas container while it is sitting inside a vehicle, trailer, trunk, or pick-up truck bed. ALWAYS place container on the ground to be filled. Keep nozzle in contact with portable container while filling. Manually control the flow of gasoline;...
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Page 30: Starting The Engine
Operation 3. Starting the Engine After you have completed the pre-start checklist procedures, you are ready to start the engine. To start the engine: 1) Disconnect all loads to the generator. 2) Turn the gasoline line valve to the ON position. 3) For cold engine, move choke lever to full choke position. -
Page 31: Checking Generator Output
Operation 4. Checking Generator Output Although the speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency, output voltage should be checked periodically to ensure the generator is working properly before connecting loads to the generator. WARNING: The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. -
Page 32: Connecting Loads
Operation 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source WARNING:... -
Page 33: Storage & Exercise
Operation Storage & Exercise When you are finished using the generator, you must: o Disconnect all loads o Shut off fuel supply o Store the generator properly o Plan on exercising the engine regularly unless the generator is prepared for long-term storage. - Page 34 Operation Prepare engine for If you will not be able to exercise the generator regularly, you must prepare the engine for long term storage to prevent gum deposits from long term storage if needed forming and causing malfunction of the engine. Prepare engine for long term storage by: o Removing all gasoline from the tank and carburetor o Adding fuel stabilizer to the gasoline (following manufacturer’s...
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Page 35: Maintenance & Repair
Repair. Major service, including the installation or replacement of parts, should be performed only by a qualified electrical service technician. Obtain factory approved parts from BRAVE Product Support at 1-800-350-8739. Replacement parts. If a part needs replacement, only use factory approved repair parts. - Page 36 If a part needs replacement, only use parts that meet the manufacturer’s specifications. Replace- ment parts that do not meet specifications may result in a safety hazard or poor operation of the generator. Any Questions, Comments, Problems, or Parts Orders Call BRAVE Product Support 1-800-350-8739...
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Page 37: Troubleshooting
Troubleshooting Problem Possible Causes Possible Remedies Engine will not a) Low oil level. a) Fill crankcase to proper oil level. start. b) Fouled spark plug. b) Clean or replace spark plug. c) Out of fuel. c) Fill fuel tank. d) Stop switch in OFF position. d) Place switch in ON position. -
Page 38: Summary Of Important Safety Information For Operation
Summary of Important Safety Information for Operation This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your generator. WARNING Carefully read and make sure you understand the following safety information before using the generator. - Page 39 Summary of Important Safety Information for Operation (cont’d) Installation / Initial Set-up Safety Dry, level surface. Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation. Block wheels if applicable. ...
- Page 40 Summary of Important Safety Information for Operation (cont’d) Fuel outdoors. Fill fuel tank outdoors – never indoors. Gasoline vapors can ignite if they collect inside an enclosure. Explosion can result. Use approved container. Never pump fuel directly into engine at gas station. Static charge can build and ignite fuel.
- Page 41 Summary of Important Safety Information for Operation (cont’d) Moving parts. Keep hands, feet, and apparel away from drive belts, fans, and other moving parts. Never remove any drive belt or fan guard while the unit is operating. Refueling. DO NOT refuel the engine until it has cooled at least two minutes. ...
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Page 42: Generator Exploded View
Generator Exploded View Rev – B.2 Item #s BRPG5500, BRPG8000, & BRPG8000ES... - Page 43 794754SO Tank bolt bar 4.33 ft. BRPG5500 1/4” fuel line hose 777345 3 ft. BRPG8000, BRPG8000ES BRPG5500 798059 798061 Brave decal BRPG8000 798062 BRPG8000ES Heat shield 794699SO BRPG5500 3/8” Spring action hose clamp 786123 BRPG8000, BRPG8000ES 797158 Made in USA decal...
- Page 44 Generator Exploded View Rev – B.2 Item # BRPG13000ES...
- Page 45 GX630 Honda engine Control panel 795895B 1/4” hose clamp 777834 3/4” heat reflective sleeving 31881 1.75 ft. 798063 Brave decal 795139SO Tank heat shield 795132SO Heat shield mount 795214SO Upper iso mount bracket, gen head 795204SO Adjustable bumper tab 787259...
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Page 46: Control Panel Parts List
Control Panel Parts List Rev – B.2 Item # BRPG5500 Item # BRPG8000 Item # BRPG8000ES... - Page 47 Control Panel Parts List Rev – B.2 Item # BRPG13000ES...
- Page 48 Control Panel Parts List Rev – B.2 Ref # Part # Description Used on BRPG5500, BRPG8000, Switch – 2 pole, red 790409 BRPG8000ES BRPG5500, BRPG8000, 783060 8 AMP Circuit Breaker BRPG8000ES 783058 300V Volt Meter BRPG5500, BRPG8000, 783059 12VDC Outlet BRPG8000ES BRPG5500 783061...
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Page 49: Generator Head Exploded View
Generator Head Exploded Views Rev – B.2 Item #s BRPG5500, BRPG8000, & BRPG8000ES... - Page 50 Generator Head Exploded Views Rev – B.2 Item #s BRPG5500, BRPG8000, & BRPG8000ES Ref # Part # Description Used On 796591 Engine Adapter BRPG5500 796580 Cover Band BRPG8000, BRPG8000ES 796578 796551 BRPG5500 Stator Assembly 796550 BRPG8000, BRPG8000ES 796586 Bearing Support 796567 Hexagon Flange Bolt M6 x 140 BRPG5500...
- Page 51 Generator Head Exploded Views Rev – B.2 Item #s BRPG13000ES...
- Page 52 Generator Head Exploded Views Rev – B.2 Item #s BRPG13000ES Ref # Part # Description 796592 Engine Adapter 796916 Cover Band 796599 Stator Assembly 796587 Bearing Support 796565 Hexagon Flange Bolt M8 x 185 795998 Carbon Brush 796564 Hexagon Flange Bolt M5 x 16 796584 End Cover 796563...
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Page 54: Limited Warranty
1-800-350-8739 prior to having any service or warranty work performed, as some services performed by parties other than Brave approved service centers may void this warranty. This limited warranty is in lieu of any other warranty expressed or implied, written or oral and Brave assumes no other responsibility or liability outside that expressed within this limited warranty. - Page 55 Serial # (i.e. BRPG5500B012345678) Signature: IMPORTANT WARRANTY INFORMATION To activate your Brave generator warranty, please fill out the information in the form above and mail to: Brave, 20195 S. Diamond Lake Rd., STE 100, Rogers, MN 55374 or go online to www.braveproducts.com...
- Page 56 20195 S. Diamond Lake Rd, Ste 100 Rogers, MN 55374 1-800-350-8739...