Briggs & Stratton PowerBoss 30201 User Manual

Manual No. 194083GS Revision 4 (07/28/2005)

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

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

Before using this product, read

this manual and follow all Safety Rules

and Operating Instructions.

CAUTION

Antes de utilizar el producto, lea

este manual y siga todas las Reglas de

Seguridad e Instrucciones de Uso.

PRECAUCIÓN

Model / Modelo

030201

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

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

PowerBOSS™ 6200W Portable Generator SAFETY RULES

TABLE OF CONTENTS

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

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 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 singlecylinder 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 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

Fire

Explosion

Toxic Fumes

Hot Surface

Electrocution

Electrical Shock

Kickback

SAVE THESE INSTRUCTIONS

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.

SAFETY RULES 6200W 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, 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.

• 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

PowerBOSS™ 6200W Portable Generator SAFETY RULES

• 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,

ect. 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

KNOW YOUR GENERATOR 6200W 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.

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.

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.

120 Volt AC, 20 Amp Duplex Receptacles

Fuel Tank

Choke Lever

Recoil Starter

Rocker Switch (on engine shroud)

Circuit Breakers (AC)

120/240 Volt AC, 30 Amp Receptacle

Spark Arrester Muffler

Air Cleaner

Grounding Fastener

Oil Fill

PowerBOSS™ 6200W 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.

Remove Generator From Carton

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

• The generator

• Generator and engine owner’s manuals

• Engine oil

• Wheel kit

Install Wheel Kit

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

You will need the following tools to install these components:

• 1/2" or 13mm wrench

• 7/16" wrench

• Socket wrench

• 1/2" or 13mm socket

• 7/16" socket

• Pliers

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 air valve facing out.

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

ASSEMBLY 6200W Portable Generator PowerBOSS™

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.

6. Repeat step 4 and 5 to secure second wheel.

7. Tip generator so that engine side is down.

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

9. Remove existing hardware from left unit vibration mount with 13mm wrench. Use same hardware to attach support leg.

10. Attach other side of support leg with M6 x 20 mm cap screw and M6 lock nut. Return generator to normal operating position (resting 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. 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 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

1.5” Air Space

Figure 2 - Fuel Expansion

PowerBOSS™ 6200W 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

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.

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.

WARNING

Figure 3 — Generator Clearance

Exhaust Port

Typical Generator Shown

OPERATION 6200W Portable Generator PowerBOSS™

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).The fuel

valve handle should be vertical (pointing toward ground) for fuel to flow.

3. Start engine according to 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”.

• 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

Fuel Valve is shown in the “On” position

Figure 4 — Fuel Valve

• 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.

• 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,

ect. can catch fire.

WARNING

PowerBOSS™ 6200W Portable Generator OPERATION

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. 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.

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 Volts AC at 30 Amps (or greater) (Figure 5).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 3,100 watts of power at

25.8 Amps for 120 Volts; 6,200 watts of power (6.2 kW) at

25.8 Amps for 240 Volts.The outlet is protected against overload by a push–to–reset circuit breaker.

120 Volt AC, 20 Amp, Duplex

Receptacle

Each duplex receptacle (Figure 6) is protected against overload by a push–to–reset 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).

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.

Figure 5 — 120/240 Volt AC, 30 Amp Receptacle

4-Wire Cord Set

240V

120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground (Green)

• 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 6 — 120 Volt AC, 20 Amp, Duplex Receptacle

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