Briggs & Stratton PowerBoss 30220 User Manual

0 (0)

Model / Modelo

030220

(7000W)

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

WARNING

Before using this product, read this manual and follow all

Safety Rules and Operating Instructions.

ADVERTENCIA

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. 199910GS Rev.A (06/21/2006)

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

PowerBOSS™	7000W Portable Generator	SAFETY RULES

SAVE THESE INSTRUCTIONS

TABLE OF CONTENTS

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

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

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

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

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.

This generator is 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 twincylinder 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 and the California Air Resources Board. 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.

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

Operator’s Manual		Electrical Shock
Explosion			Fire
Toxic Fumes	Kickback		Hot Surface

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.

SAFETY RULES	7000W Portable Generator	PowerBOSS™

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 ONLY use outdoors and or in partly enclosed far from open windows, areas such as garages. doors, and vents.

WARNING

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

Breathing carbon monoxide can 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 (even if doors or windows are open), 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 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

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.

•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.

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.

PowerBOSS™	7000W 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

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.

•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

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.

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.

FEATURES	7000W Portable Generator	PowerBOSS™

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

Hour Meter

Spark Arrester Muffler

120 Volt AC, 20 Amp
Duplex Receptacles
Circuit Breakers (AC)
Rocker Switch
Circuit Breaker
120/240 Volt AC,
30 Amp Receptacle
Grounding Fastener	Data Tag	Oil Fill Cap
	Data Tag

	Choke Rod
	Air Cleaner	Engine Switch
	Air Cleaner
	Recoil Starter

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 Rod — Used when starting a cold engine.

Circuit Breakers (AC) — The 120 Volt AC, 20A duplex receptacles are provided with "push to reset" circuit breakers 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.

Engine Switch — Set this switch to "On" before using recoil starter. Set switch to "Off" to switch off engine.

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

Grounding Fastener — Consult your local agency having jurisdiction for grounding requirements in your area.

Hour Meter — Displays and records how many hours your generator has run (up to 9,999.9).

Oil Fill Cap — Check and fill engine with oil here.

Recoil Starter — Used to start the engine.

Rocker Switch Circuit Breaker — The 120/240 Volt AC, 30A locking receptacle is provided with a rocker switch circuit breaker to protect the generator against electrical overload.This switch also controls all receptacles.

Spark Arrester Muffler — Exhaust muffler lowers engine noise and is equipped with a spark arrester screen.

PowerBOSS™	7000W 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 “Know Your Generator” for data tag location.

Unpacking the Generator

1.Set the carton on a rigid flat surface.

2.Open carton completely by cutting each corner from top to bottom.

3.Remove everything from carton except generator.

4.Leave generator on carton to install wheel kit.

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.

Figure 1 — Install Wheel Kit

Handle Pin
45 mm Cap Screw	Nylon Washers
45 mm Cap Screw
	Lock Nut

Flat Washers

Handle

Support Leg

You will need the following tools to install this wheel kit:

•13mm socket wrench

•13mm open end wrench

•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.Slide a wheel over the axle.

NOTE: Be sure to install both wheels with the air pressure valve on the outboard side.

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

CAUTION

E-rings can cause eye injury.

E-rings can spring back and become airborne when installing or removing.

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

5.Install e-ring with pliers, squeezing from top of e-ring to bottom of axle.

Wheel

Flat Washer

Axle

20mm Cap Screw

E-Ring

Lock Nut

ASSEMBLY	7000W Portable Generator	PowerBOSS™

6.Repeat step 3 thru 5 to secure second wheel.

7.Tip generator so that engine side is down.

8.Attach support leg with M8 x 20 mm cap screws and M8 lock nuts.

9.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.

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

11.Loop handle pins to generator frame as shown in Figure 1. Raise handles and insert handle pins to move generator.

12.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 operator’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 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).

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.

•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.

1.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 at least 1.5" of tank space for fuel expansion (Figure 2).

Figure 2 - Fuel Expansion

	AirSpace	Tank
		Fuel
	1.5”

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

PowerBOSS™	7000W 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 (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 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 Location

Generator Clearance

WARNING

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

•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.

NEVER use in the home ONLY use outdoors and or in partly enclosed far from open windows, areas such as garages. doors, and vents.

Figure 3 — Generator Clearance

Typical Generator Shown

OPERATION	7000W 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.

Figure 4 — Fuel Valve

Fuel Valve is shown in “On” position

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

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

•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.

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”.

CAUTION

Exceeding generator’s 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.

PowerBOSS™	7000W 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 operator’s manual.

4.Move fuel valve to “Off” position.

RECEPTACLES

CAUTION

Receptacles may be marked with rating value greater than generator output capacity.

•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”.

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA L14–30 (National Electrical Manufacturers Association) plug with this receptacle. Connect a 4–wire cord set rated for 250 Volt AC loads at 30 Amps (or greater) (Figure 5).You can use the same 4–wire cord if you plan to run a 120 Volt load.

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

4-Wire Cord Set

240V

120V 120V

W (Neutral)

Y (Hot)	X (Hot)
NEMA L14-30	Ground (Green)

This receptacle powers 120/240 Volt AC, 60 Hz, single phase loads requiring up to 3,500 watts of power at

29.1 Amps for 120 Volts; 7,000 watts of power (7.0 kW) at 29.1 Amps for 240 Volts.The outlet is protected by a rocker switch circuit breaker.

120 Volt AC, 20 Amp, Duplex

Receptacle

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

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

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 operator’s manual).

4.Check oil level daily or after every eight (8) hours of operation.

5.Maintain generator following “Maintenance Schedule” in engine operator’s manual.

6.Shelter unit from elements.

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