PowerBoss 30230
Manual No. 197106GS Rev. B (06/14/2006)
BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC
JEFFERSON,WISCONSIN, U.S.A.
Operator’s Manual
Manual del Operario
Questions? Help is just a moment away!
Preguntas? La ayuda es justa un momento lejos!
Call: Generator Helpline / Llamada: Generador Helpline
1-800-743-4115 M-F 8-5 CT
web: www.briggsandstratton.com
PowerBOSS™ is a trademark of Briggs & Stratton Power Products.
PowerBOSS™ es una marca registrada de Briggs & Stratton Power Products.
Model / Modelo
030230
(5600W)
Before using this product, read this manual and follow all
Safety Rules and Operating Instructions.
WARNING
Antes de utilizar el producto, lea este manual y siga todas las
Reglas de Seguridad e Instrucciones de Uso.
ADVERTENCIA
2
PowerBOSS™ 5600W Portable Generator SAFETY RULES
TABLE OF CONTENTS
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EQUIPMENT
DESCRIPTION
Read this manual carefully and become
familiar with your generator. Know its
applications, its limitations and any hazards
involved.
The generators are an engine–driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible electrical
lighting, appliances, tools and motor loads.The generator’s
revolving field is driven at about 3,600 rpm by a single-
cylinder engine.
CAUTION! DO NOT exceed the generator’s
wattage/amperage capacity. See “Don’t Overload
Generator”.
Every effort has been made to ensure that information in
this manual is accurate and current. However, we reserve
the right to change, alter or otherwise improve the product
and this document at any time without prior notice.
The Emission Control System for this generator is
warranted for standards set by the Environmental
Protection Agency. For warranty information refer to the
engine operator’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
SAVE THESE INSTRUCTIONS
Copyright © 2006 Briggs & Stratton Power Products
Group, LLC. All rights reserved. No part of this material
may be reproduced or transmitted in any form by any
means without the express written permission of Briggs &
Stratton Power Products Group, LLC.
Fire
Explosion
Toxic Fumes
Hot Surface
Electrical Shock
Kickback
Operator’s Manual
Flying Objects
3
SAFETY RULES 5600W Portable Generator PowerBOSS™
• 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 death or serious injury and/or
property damage.
WARNING
• 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 or wet weather.
• 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.
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
(even if doors or windows are open),including the generator
compartment of a recreational vehicle (RV).
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide can cause nausea,
fainting or death.
WARNING
WHEN ADDING OR DRAINING FUEL
• Turn generator OFF and let it cool at least 2 minutes before
removing fuel cap.Loosen cap slowly to relieve pressure in
tank.
• Fill or drain fuel tank outdoors.
• DO NOT overfill tank.Allow space for fuel expansion.
• Wait for spilled fuel to evaporate before starting engine.
• 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.
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
Using a generator indoors WILL KILL YOU
IN MINUTES.
Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.
NEVER use in the home
or in partly enclosed
areas such as garages.
ONLY use outdoors and
far from open windows,
doors, and vents.
4
PowerBOSS™ 5600W Portable Generator SAFETY RULES
• 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
• 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 and avoid hot exhaust gases.
• Allow equipment to cool before touching.
• Keep at least 5 ft. (152 cm) clearance on all sides of generator
including overhead.
• Code of Federal Regulation (CFR) Title 36 Parks, Forests,and
Public Property require equipment powered by an internal
combustion engine to have a spark arrester, maintained in
effective working order, complying to USDA Forest service
standard 5100-1C or later revision. In the State of California a
spark arrester is required under section 4442 of the California
Public resources code. Other states may have similar laws.
Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).
Severe burns can occur on contact.
Exhaust heat/gases can ignite combustibles,
structures or damage fuel tank causing a fire.
WARNING
5
FEATURES 5600W Portable Generator PowerBOSS™
120 Volt AC, 20 Amp, Duplex Receptacles — May be
used to supply electrical power for the operation of
120 Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting,
appliance, tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle — May
be used to supply electrical power for the operation of
120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical, lighting, appliance, tool and motor loads.
Air Cleaner —
Protects engine by filtering dust and debris
out of intake air.
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Push to reset circuit breakers are
provided to protect the generator against electrical overload.
Data Tag — Provides model, revision and serial number of
generator. Please have these readily available when calling
for assistance.
Fuel Tank — Capacity of seven (7) U.S. gallons.
Grounding Fastener — Consult your local agency having
jurisdiction for grounding requirements in your area.
Oil Fill Cap/Dipstick — Check and fill engine with oil
here.
Recoil Starter — Used to start the engine.
Rocker Switch — Set this switch to "On" before using
recoil starter. Set switch to "Off" to switch off engine.
KNOW YOUR GENERATOR
Read this operator’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.
Fuel Tank
Air
Cleaner
Rocker Switch
120/240 Volt AC,
30 Amp Receptacle
Circuit Breakers
Choke Lever
Recoil Starter
Grounding Fastener
Oil Fill Cap/Dipstick
120 Volt AC, 20 Amp
Duplex Receptacles
Data Tag
6
PowerBOSS™ 5600W Portable Generator ASSEMBLY
ASSEMBLY
Your generator requires some assembly and is ready for
use after it has been properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the generator helpline at
1-800-743-4115. If calling for assistance, please have the
model, revision, and serial number from the data tag
available. See “Features and Controls” for data tag location.
Unpack the Generator
1. Set the carton on a rigid flat surface.
2. Remove everything from carton except generator.
3. Open carton completely by cutting each corner from
top to bottom.
4. Leave generator on carton to install wheel kit.
Carton Contents
Check all contents against those listed below:
• Main unit
• Engine oil
• Operator’s manual
• Engine operator’s manual
• Wheel kit
If any parts are missing or damaged, call the generator
helpline at 1-800-743-4115.
Install Wheel Kit
NOTE:Wheel kit is not intended for over-the-road use.
You will need the following tools to install these
components:
• 2 - 13mm wrenches
• Socket wrench with a 13mm socket
• Pliers
• Safety glasses
Refer to Figure 1 and install the wheel kit as follows:
1. Tip generator so that engine end is up.
2. Slide axle through both mounting brackets.
3. Place a wheel on each side with raised hub inboard.
4. Place a washer on axle and then place an e-ring in axle
groove.
5. Install e-ring with pliers, squeezing from top of e-ring
to bottom of axle.
Capscrew
Handle
Mounting Leg
E-Ring
Wheel
Washer
Axle
Nut
Capscrew
Nut
Figure 1 — Install Wheel Kit
• Always wear eye protection when installing/removing e-rings.
E-rings can cause eye injury.
E-rings can spring back and become airborne
when installing or removing.
CAUTION
7
ASSEMBLY 5600W Portable Generator PowerBOSS™
6. Repeat step 4 and 5 to secure second wheel.
7. Tip generator so that engine side is down.
8. Attach support leg with M8 x 20 mm capscrews and
M8 lock nuts.
9. Center the handle bracket on generator frame at
support leg end of cradle, as shown.
10. Attach handle using two long (M8 x 45mm) cap screws
and two locking (M8) hex nuts.Tighten with a 13mm
socket and wrench.
11. Return generator to normal operating position (resting
on wheels and support leg).
BEFORE STARTING THE
ENGINE
Add Engine Oil
• Place generator on a level surface.
• Refer to engine operator’s manual and follow oil
recommendations and instructions.
NOTE: Check oil often during engine break–in. Refer to
engine operator’s manual for recommendations.
NOTE:The alternator 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 87 octane. DO NOT use fuel which
contains Methanol. DO NOT mix oil with fuel.
2. Clean area around fuel fill cap, remove cap.
3. Slowly add regular unleaded fuel to fuel tank. Be careful
not to overfill.Allow at least 1.5" of tank space for fuel
expansion (Figure 2).
4. Install fuel cap and let any spilled fuel evaporate before
starting engine.
CAUTION
• Refer to engine operator’s 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.
Fuel
Tank
1.5” Air Space
Figure 2 - Fuel Expansion
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.
• Wait for spilled fuel to evaporate before starting engine.
• 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
8
PowerBOSS™ 5600W Portable Generator OPERATION
USING THE GENERATOR
System Ground
The generator has a system ground that connects the
generator frame components to the ground terminals on
the AC output receptacles.The system ground is connected
to the AC neutral wire (the neutral is bonded to the
generator frame).
Special Requirements
There may be Federal or State Occupational Safety and
Health Administration (OSHA) regulations, local codes, or
ordinances that apply to the intended use of the generator.
Please consult a qualified electrician, electrical inspector, or
the local agency having jurisdiction.
• In some areas, generators are required to be registered
with local utility companies.
• If the generator is used at a construction site, there may
be additional regulations which must be observed.
Connecting to a Building’s Electrical
System
Connections for standby power to a building’s electrical
system must be made by a qualified electrician.The
connection must isolate the generator power from utility
power, and must comply with all applicable laws and
electrical codes.
Generator Location
Generator Clearance
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 or wet weather.
• 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.
WARNING
Figure 3 — Generator Clearance
Typical Generator Shown
• Keep at least 5 ft. (152 cm) clearance on all sides of generator
including overhead.
Exhaust heat/gases can ignite combustibles,
structures or damage fuel tank causing a fire.
WARNING
Using a generator indoors WILL KILL YOU
IN MINUTES.
Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.
NEVER use in the home
or in partly enclosed
areas such as garages.
ONLY use outdoors and
far from open windows,
doors, and vents.
9
OPERATION 5600W Portable Generator PowerBOSS™
OPERATING THE
GENERATOR
Starting the Engine
Disconnect all electrical loads from the generator. Use the
following start instructions:
1. Make sure unit is on a level surface.
IMPORTANT: Failure to start and operate unit on a level
surface will cause the unit not to start or shut down during
operation.
2. Turn the fuel valve to the “On” position (Figure 4).The
fuel valve handle should be vertical (pointing toward
the ground) for fuel to flow.
3. Start engine according to instructions given in the
engine operator’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 operator’s 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”.
Fuel Valve is shown
in the On position
Figure 4 — Fuel Valve
• See “Don’t Overload Generator”.
• Start generator and let engine stabilize before connecting
electrical loads.
• Connect electrical loads in OFF position, then turn ON for
operation.
• Turn electrical loads OFF and disconnect from generator
before stopping generator.
Exceeding generators wattage/amperage capacity can
damage generator and/or electrical devices connected
to it.
CAUTION
• When 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
• DO NOT touch hot surfaces and avoid hot exhaust gases.
• Allow equipment to cool before touching.
• Keep at least 5 ft. (152 cm) clearance on all sides of generator
including overhead.
• Code of Federal Regulation (CFR) Title 36 Parks, Forests,and
Public Property require equipment powered by an internal
combustion engine to have a spark arrester, maintained in
effective working order, complying to USDA Forest service
standard 5100-1C or later revision. In the State of California a
spark arrester is required under section 4442 of the California
Public resources code. Other states may have similar laws.
Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).
Severe burns can occur on contact.
Exhaust heat/gases can ignite combustibles,
structures or damage fuel tank causing a fire.
WARNING
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