Briggs & Stratton PowerBoss 30227 User Manual

0 (0)

Model / Modelo

030227

(6500W)

Owner’s Manual

Manual del Propietario

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

CAUTION

Before using this product, read this manual and follow all

Safety Rules and Operating Instructions.

PRECAUCIÓN

Antes de utilizar el producto, lea este manual y siga todas las Reglas de Seguridad e Instrucciones de Uso.

PowerBOSS™ is a trademark of Briggs & Stratton Power Products.

PowerBOSS™ es una marca registrada de Briggs & Stratton Power Products.

Manual No. 196415GS Rev. 0 (03/02/2005)

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

PowerBOSS™

6500W Portable Generator

SAFETY RULES

 

 

 

SAVE THESE INSTRUCTIONS

TABLE OF CONTENTS

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

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

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

EQUIPMENT

DESCRIPTION

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

The generator described herein is an engine-driven, revolving field, alternating current (AC) device. Each is designed to supply electrical power for operating compatible electrical lighting, appliance, tool, and motor loads. Each unit's revolving field rotates at about 3,600 rpm.

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 these unit’s are 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.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Hazard Symbols and Meanings

Electrocution

Electrical Shock

Electrical Shock

Explosion

Fire

Toxic Fumes

Kickback

Hot Surface

Copyright © 2005 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.

2

SAFETY RULES

6500W Portable Generator

PowerBOSS™

 

 

 

WARNING

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

Breathing carbon monoxide will cause nausea, fainting or death.

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).

WARNING

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.

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.

WARNING

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

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

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.

3

PowerBOSS™

6500W Portable Generator

SAFETY RULES

 

 

 

WARNING

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.

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.

WARNING

Unintentional sparking can result in fire or electric shock.

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.

WARNING

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.

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.

CAUTION

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

Excessively low speeds impose a heavy load.

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.

CAUTION

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

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.

CAUTION

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

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.

4

Briggs & Stratton PowerBoss 30227 User Manual

FEATURES

6500W Portable Generator

PowerBOSS™

 

 

 

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.

Recoil Starter

Choke Lever

 

Rocker Switch (on engine shroud)

Start Button

Battery Float Charger

Oil Fill

Grounding Fastener

Air Cleaner

Spark Arrester Muffler

Fuel Tank

Circuit

Breakers (AC)

120/240 Volt AC,

30 Amp Receptacle

120 Volt AC, 20 Amp

Duplex Receptacles

120 Volt AC, 20 Amp, Duplex Receptacle — 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.

Battery Float Charger — Use battery float charger jack to keep the starting battery charged and ready for use.

Choke Lever — Used when starting a cold engine.

Circuit Breakers (AC) — Push-to-reset circuit breakers are provided to protect generator against electrical overload. Fuel Tank — Capacity of seven (7) U.S. gallons.

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

Oil Fill — Add engine 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.

Spark Arrester Muffler — Exhaust muffler lowers engine noise and is equipped with a spark arrester screen. Start Button — Push to start the engine.

5

PowerBOSS™

6500W Portable Generator

ASSEMBLY

 

 

 

ASSEMBLY

ELECTRIC START

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

If you have any problems with the assembly of your generator, please call the generator helpline at 1-800-743-4115. If calling for assistance, please have the model, revision, and serial number from the data tag available.

Remove Generator From Carton

1.Set 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.

Main unit

Engine oil

Owner’s manual

Engine manual

Battery float charger

Wheel kit

Your unit is equipped with electric start capability but can be started manually. If you choose not to use the electric start feature, you do not need to connect the negative battery cable.

Check Battery / Attach Negative

Battery Wire

The sealed battery on the generator is fully charged and pre–installed except for the negative (black) battery cable.

To install:

1.Cut off tie wrap securing loose end of negative (black) cable.

2.Remove screw, lock washer and flat washer on negative battery terminal.

3.Slide lock washer, flat washer and negative battery cable over screw (Figure 1).

Figure 1 — Negative Battery Connection

Negative

 

Battery Cable

 

Screw

 

Lock Washer

Flat Washer

4.Reattach screw to negative battery terminal and tighten.

5.Verify that connections to battery and generator are tight and secure.

6

ASSEMBLY

6500W Portable Generator

PowerBOSS™

 

 

 

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 the following tools to install this wheel kit:

1/2" or 13mm socket wrench

1/2" or 13mm open end wrench

7/16" socket wrench

7/16" open end wrench

Needle-nose pliers

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

Refer to Figure 2 and install the wheel kit as follows:

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

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

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.

10.Attach support leg with M8 x 20 mm cap screws and M8 lock nuts. Rest generator on wheels and support leg.

11.Attach handles to handle brackets on generator frame, as shown in Figure 2, with M8 x 45 mm capscrews, flat washers, nylon washers, and M8 lock nuts.

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

12.Loop handle pins to generator frame as shown in Figure 2. 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.

Figure 2 — Install Wheel Kit

Handle Pin

Typical Generator Shown

Nylon Washer

 

 

Nylon Washer

45 mm Cap Screw

 

Flat Washer

Wheel

Nut

Handle

Flat Washer

1/4-20 Nut

Axle

 

 

 

 

20 mm Cap Screw

 

M8 Nut

 

E-Ring

Vibration Mount

Support Leg

 

 

 

3/4” Cap Screw

M8 Nut

 

7

PowerBOSS™

6500W Portable Generator

ASSEMBLY

 

 

 

BEFORE STARTING THE ENGINE

Add Fuel

NOTE: This gasoline engine is certified to operate on gasoline. Exhaust Emission Control System: EM (Engine Modifications).

Add Engine Oil

Place generator on a level surface.

Refer to engine owner’s manual and follow oil recommendations and instructions.

CAUTION

Any attempt to crank or start the engine before it has been properly filled with the recommended oil will result in equipment failure.

Refer to engine manual for oil fill information.

Damage to equipment resulting from failure to follow this instruction will void warranty.

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.

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

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.

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

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

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

Figure 3 - Fuel Expansion

AirSpace

Tank

Fuel

1.5”

 

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

8

OPERATION

6500W Portable Generator

PowerBOSS™

 

 

 

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.

WARNING

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.

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 Location

Generator Clearance

WARNING

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

Breathing carbon monoxide will cause nausea, fainting or death.

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).

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 4). Prevailing winds and air currents should be taken into consideration when positioning generator.

Figure 4 — Generator Clearance

Typical Generator Shown

Exhaust Port

9

PowerBOSS™

6500W Portable Generator

OPERATION

 

 

 

OPERATING THE

GENERATOR

CAUTION

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

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.

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 to shut down during operation.

2.Turn the fuel valve to the “On” position (Figure 5).The fuel valve handle should be vertical (pointing toward the ground) for fuel to flow.

Figure 5 — Fuel Valve

Fuel Valve is shown in the On position

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

WARNING

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.

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.

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.

WARNING

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.

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.

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 the Generator”.

Stopping the Engine

1.Unplug all electrical loads from generator panel receptacles. Never start or stop engine with electrical devices plugged in and turned ON.

2.Let engine run at no-load for several minutes to stabilize internal temperatures of engine and generator.

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

4.Move fuel valve to “Off” position.

10

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