Briggs & Stratton PowerBOSS 030255 Operator's Manual

SAVE THESE iNSTRUCTiONS

TABLE OF CONTENTS

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

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

Assembly ...................................... 6=7

Operation .................................... 8= I I

Specifications ................................... 12

Maintenance .................................... [2

Storage ........................................ 13

Troubleshooting ................................. 14

Warranty ...................................... [5

EQUIPMENT

DESCRiPTiON

_ Read this manual carefully and become

............................... familiar with your generator Know its

applications, its limitations and any hazards

involved

The generators described herein are 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".

SAFETY RULES

_l_ 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.

[ AwAR-I-G

The engine exhaust from this product contains

Ichemicals known to the State of California to cause
lcancer, birth defects, or other reproductive harm.

Hazard Symbols and Meanings

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 and the California Air Resources Board.
For warranty information refer to the Engine Operator's

Manual.

Copyright © 2006 Brigs & Stratton Power Products
Group, LLC. Allrights 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.

Operator's Manual

Explosion

Toxic Fumes

Fire

Kickback

Electrical Shock

Flying Objects

Hot Surface

Using a generator indoors WILL KILL YOU

IN MINUTES.

|WARNING

Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.

J

[]

NEVER use in the home

or in partly enclosed
areas SUChas garages.

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).

WARNING

ONLY use outdoors and
far from open windows,

doors, and vents.

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.

If fuel spills, wait until it evaporates before starting engine.
Keep fuel away from sparks, open flames, pilot lights, heat, and

other ignition sources.
DO NOT light a cigarette or smoke.

NHEN 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.

NHEN 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.

. 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.

|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 death or serious injury and/or

property damage.

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.

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.

WARNING

WHEN ADJUSTING OR PIAKING REPAIRSTOYOUR

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.

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

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

Use generator only for intended uses.
If you have questions about intended use, as[< 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.

KNOWYOUR 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.

Alternator may vary

slightly in appearance Fuel Tank
from that shown here

Rocker Switch

!!

Circuit /
Breakers (AC) 30 Amp Receptacle

120/240 Volt AC,

/

120Volt AC, 20 Amp

Duplex Receptacle

120 Volt AC, 20 Amp, Duplex Receptacle -- May be

used to supply electrical power for the operation of

120Vok AC, 20 Amp, single phase, 60 Hz electrical, lighting,

appliance, tool and motor loads.

120/240Volt AC, 30 Amp Locking Receptacle -- May

be used to supply electrical power for the operation of

120 and/or 240Volt AC, 30Amp, single phase, 60 Hz

electrical, lighting, appliance, tool and motor loads.

Air Cleaner -- Protects engine by filtering dust and

debris out of intake air.
Choice lever -- Used when starting a cold engine.

Choke Lever

Grounding
Fastener

Spark Attester

I

Air Cleaner

Recoil Starter

Muffler

Circuit Breakers (AC) -- Push-to-reset circuit breakers

are provided to protect the generator against electrical
overload.

Fuel Tank -- Capacity of seven (7) U.S. gallons (26.51).

Grounding Fastener -- Consult your local agency having

jurisdiction for grounding requirements in your area.

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 Attester Muffler- Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.

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 heIpline at

1-800-743-4115. If calling for assistance, please have the

model, revision, and serial number from the data tag available.

Unpacking the Generator

I. 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. If any parts are missing or damaged, call
the generator heIpline at 1-800-743-4115.

• The generator

• Generator operator's manual

• Engine operator's manual

• Engine oil

• Three packets of fuel stabilizer

• 30Amp extension cord

• Wheel kit

InstallWheel Kit

NOTE: Wheel kit is not intended for over=the-road use.

You will need the following tools to install these

components:

• 2 = 13ram wrenches

• Socket wrench with a 13mm socket

• Pliers

• Safety glasses

Refer to Figure I and installthe wheel kitas follows:

I. Tip generator so that engine end is up.

2. Slide axle through both mounting brackets.

3. Place a wheel on each side with air valve facing out.

4. Place a washer on axle and then place an e-ring in axle

groove.

S. Install e-ring with pliers, squeezing from top of e-ring

to bottom of axle.

CAUTION

Always wear eye protection when installing/removing e-rings.

Capscrew

Nut

Handle

Support Leg_QJI

Washer

Axle

Capscrew ?

i_ Nut Wheel E-Ring

6. Repeatstep 4 and 5 to secure second wheel.

7. Tip generator so that engine side is down.

8. Line up holes in support leg with holes in generator
frame.

9. Attach support leg using 2 capscrews (M8 x 16 mm)
and 2 hex nuts.Tighten with a 13mm socket wrench

and 13mm wrench.

IO. On support leg end of generator, slide handle onto

center of top of frame.

I I. Attach handle using two long (MS x 45mm) cap screws

and two locking (MS) hex nuts.Tighten with a 13mm
socket and wrench.

12. Return generator to normal operating position (resting
on wheels and support leg).

BEFORE STARTING THE

ENGINE

Add Fuel

NOTE: This gasoline engine is certified to operate on

gasoline. Exhaust Emission Control System: EM (Engine

Modifications).

|WARNING

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.

. Fillfuel 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.

Add Engine Oil

• Place generator on a level surface.

CAUTION

. Refer to engine manual for oil fill information.
. Damage to equipment resulting from failure to follow this

instruction will void warranty.

• 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.

I. Use clean, fresh, regular UNLEADED gasoline 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 about 1.5" (4cm) of tank space

for fuel expansion (Figure 2).

4. Install fuel cap and let any spilled fuel evaporate before
starting engine.

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

WARNING

Keep at least 5 ft. (152 cm) clearance on all sides of generator
including overhead.

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.

Using a generator indoors WILL KILL YOU

iN MINUTES.

Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.

[]

_ 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.

. 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.

NEVER use in the home

or in partly enclosed
areas SUChas garages.

ONLY use outdoors and
far from open windows,

doors, and vents.

Typical Generator Shown

Exhaust Port

OPERATING THE

GENERATOR

Startin ine

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

I. 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 4).The
fuel valve handle should be vertical (pointing toward
the ground) for fuel to flow.

FuelValve is shown
in the On position

3. Start engine according to instructions given in the
engine operator's manual.

I WARNING

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 attester is required under section 4442 of the California

Public resources code. Other states may have similar laws.

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 240Volt loads to the 120Vo[t duplex
receptacles.

• DO NOT connect 3-phase loads to the generator.

1

• DO NOT connect 50 Hz loads to the generator.

• DO NOT OVERLOAD THE GENERATOR. See

"Don't Overload the Generator".

. 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.

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.