PowerBoss 030665-01, 030666-02 Operator's Manual

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Portable Generator

Operator’s Manual

Generator certified in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-14, Motors and Generators.

BRIGGS & STRATTON CORPORATION

MILWAUKEE, WISCONSIN, U.S.A.

Manual No. 80021673 Revision -

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Thank you for purchasing this quality-built PowerBoss® generator. We are pleased that you’ve placed your confidence in the PowerBoss brand. When operated and maintained according to the instructions in this manual, your PowerBoss generator will provide many years of dependable service.

This manual contains safety information to make you aware of the hazards and risks associated with generator products and how to avoid them. This generator is designed and intended only for supplying electrical power for operating compatible electrical lighting, appliances, tools and motor loads, and is not intended for any other purpose. It is important that you read and understand these instructions thoroughly before attempting to start or operate this equipment. Save these original instructions for future reference.

This generator requires final assembly before use. Refer to the Assembly section of this manual for instructions on final assembly procedures. Follow the instructions completely.

Where to Find Us

You never have to look far to find Briggs & Stratton support and service for your generator. Consult your Yellow Pages. There are over 30,000 Briggs & Stratton authorized service dealers worldwide who provide quality service. You can also contact Briggs & Stratton Customer Service by phone at (800) 743-4115, or on the Internet at www.powerboss-equipment.com.

Generator

Model Number _____________________________

Revision __________________________________

Serial Number ______________________________

Date Purchased ___________________________

Engine

Model Number _____________________________

Type Number ______________________________

Serial Number ______________________________

Table of Contents

Operator Safety..................................................3

Assembly.......................................................8

Features and Controls ...........................................11

Operation......................................................13

Maintenance ...................................................16

Troubleshooting ................................................20

Warranty ......................................................22

Product Specifications ...........................................24

Common Service Parts ..........................................24

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Operator Safety

Safety Labels

The generator safety labels shown below and on the next page are placed on your portable generator to draw attention to potential safety hazards.

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Equipment Description

Read this manual carefully and become

familiar with your generator. Know its applications, its limitations and any hazards involved.

The 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 single-cylinder engine.

Safety Symbols and Meanings

Toxic Fumes

Fire

Kickback

Explosion

Electrical Shock

Operator’s Manual

NOTICE

capacity could damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage capacity. See Generator Capacity.

Every effort has been made to ensure that the information in this manual is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise improve the generator and this documentation 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.

This spark ignition system complies with the Canadian standard ICES-002.

Exceeding generators wattage/amperage

Important Safety Information

The manufacturer cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and the tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique that the manufacturer does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure that the procedure, work method or operating technique that you choose does not render the generator unsafe.

Moving Parts

The safety alert symbol indicates a potential

personal injury hazard. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to designate a degree or level of hazard seriousness. A safety symbol may be used to represent the type of hazard. The signal word NOTICE is used to address practices not related to personal injury.

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,

could result in minor or moderate injury. NOTICE

not hazard-related.

indicates information considered important, but

Flying Objects

Hot Surface

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WARNING The engine exhaust from this

product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING Certain components in this product

and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.

WARNING POISONOUS GAS HAZARD.

Engine exhaust contains carbon monoxide, a poisonous gas that could kill you in

minutes. You CANNOT smell it, see it, or taste it. Even if you do not smell exhaust fumes, you could still be exposed to carbon monoxide gas.

• Operate this product ONLY outside far away from windows, doors and vents to reduce the risk of carbon monoxide gas from accumulating and potentially being drawn towards occupied spaces.

• Install battery-operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up according to the manufacturer’s instructions. Smoke alarms cannot detect carbon monoxide gas.

• DO NOT run this product inside homes, garages, basements, crawlspaces, sheds, or other partiallyenclosed spaces even if using fans or opening doors and windows for ventilation. Carbon monoxide can quickly build up in these spaces and can linger for hours, even after this product has shut off.

• ALWAYS place this product downwind and point the engine exhaust away from occupied spaces.

If you start to feel sick, dizzy, or weak while using this

product, shut it off and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

WARNING Starter cord kickback (rapid

retraction) will pull hand and arm toward engine faster than you can let go which could cause broken bones, fractures,

bruises, or sprains resulting in serious injury.

• 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 Fuel and its vapors are extremely

flammable and explosive which could cause burns, fire or explosion resulting in death or serious injury.

WHEN ADDING OR DRAINING FUEL

• Turn generator engine 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.

• Check fuel lines, tank, cap and fittings frequently for cracks or leaks. Replace if necessary.

• 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 operate this product inside any building, carport, porch, mobile equipment, marine applications, or enclosure.

• DO NOT tip engine or equipment at angle which causes fuel to spill.

• DO NOT stop engine by moving choke control to CHOKE

( ) position.

WHEN TRANSPORTING, MOVING OR REPAIRING EQUIPMENT

• Transport/move/repair with fuel tank EMPTY or with fuel shutoff valve OFF.

• DO NOT tip engine or equipment at angle which causes fuel to spill.

• Disconnect spark plug wire.

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 could 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.

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WARNING

electrical shock or burn resulting in death or serious injury.

Generator voltage could cause

WARNING Starter and other rotating parts

could entangle hands, hair, clothing, or accessories resulting in serious injury.

• Use listed transfer equipment, suitable for the intended use, to prevent backfeed by isolating generator from electric utility workers.

• When using generator for backup power, notify utility company.

• 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 Exhaust heat/gases could ignite

combustibles, structures or damage fuel tank causing a fire, resulting in

death or serious injury. Contact with muffler area could cause burns resulting in serious injury.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

• It is a violation of California Public Resource Code, Section 4442, to use or operate the engine on any forestcovered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws.

Contact the original equipment manufacturer, retailer, or

dealer to obtain a spark arrester designed for the exhaust system installed on this engine.

• Replacement parts must be the same and installed in the same position as the original parts.

WARNING Unintentional sparking could cause

fire or electric shock resulting in death or serious injury.

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.

• NEVER operate generator without protective housing or covers.

• DO NOT wear loose clothing, jewelry or anything that could be caught in the starter or other rotating parts.

• Tie up long hair and remove jewelry.

CAUTION Excessively high operating speeds

could result in minor injury. Excessively low operating speeds impose a heavy load.

• DO NOT tamper with governor spring, links or other parts to increase engine speed. Generator supplies correct rated frequency and voltage when running at governed speed.

• DO NOT modify generator in any way.

NOTICE

capacity could damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage capacity. See Generator Capacity.

• 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.

NOTICE

damage it and shorten its life.

• Use generator only for intended uses.

• If you have questions about intended use, ask dealer or contact local service center.

• 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.

Exceeding generators wattage/amperage

Improper treatment of generator could

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Assembly

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

If you have any problems with the assembly of your generator, please call the generator helpline at (800) 743-4115. If calling for assistance, please have the model, revision, and serial number from the identification label available. See Generator Features and Controls for identification label location.

Unpack 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.

The generator is supplied with:

• Operator’s manual

• Engine oil bottle

Add Engine Oil

1. Place generator on a level surface.

2. Clean area around oil fill and remove yellow oil fill cap/dipstick.

3. Using oil funnel (optional), slowly pour contents of provided oil bottle into oil fill opening to the FULL mark (A) on dipstick.

To protect the fuel system from gum formation, mix in a fuel stabilizer when adding fuel. See Storage. All fuel is not the same. If you experience starting or performance problems after using fuel, switch to a different fuel provider or change brands. This engine is certified to operate on gasoline. The emission control system for this engine is EM (Engine Modifications).

WARNING Fuel and its vapors are extremely

flammable and explosive which could cause burns, fire or explosion resulting in death or serious injury.

WHEN ADDING FUEL

• Turn generator engine 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.

• If fuel spills, wait until it evaporates before starting engine.

• Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.

• Check fuel lines, tank, cap and fittings frequently for cracks or leaks. Replace if necessary.

• DO NOT light a cigarette or smoke.

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

2. Slowly add unleaded gasoline (B) to fuel tank (C). Be careful not to fill above the baffle (D). This allows adequate space for fuel expansion as shown.

TANK

FUEL

NOTICE

damage it and shorten its life.

• DO NOT attempt to crank or start the engine before it has been properly serviced with the recommended oil. This could result in an engine failure.

4. Replace oil fill cap/dipstick and fully tighten.

Improper treatment of generator could

Add Fuel

Fuel must meet these requirements:

• Clean, fresh, unleaded fuel.

• A minimum of 87 octane/87 AKI (91 RON). For

high altitude use, see High Altitude.

• Fuel with up to 10% ethanol (gasohol) is acceptable.

NOTICE Use of unapproved fuels could damage generator and voids warranty.

• DO NOT use unapproved fuel such as E15 and E85.

• DO NOT mix oil in fuel or modify engine to run on alternate fuels.

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

High Altitude

At altitudes over 5,000 ft. (1524 m), a minimum 85 octane / 85 AKI (89 RON) gasoline is acceptable. To remain emissions compliant, high altitude adjustment is required. Operation without this adjustment will cause decreased performance, increased fuel consumption, and increased emissions. See a Briggs & Stratton Authorized Dealer for high altitude adjustment information. Operation of the engine at altitudes below 2,500 ft. (762 m) with the high altitude kit is not recommended.

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System Ground

The generator neutral is floating, which means that the AC stator winding is isolated from the grounding fastener and the AC receptacle ground pins. On a floating neutral generator the AC receptacle ground pins are not functional. Electrical devices, such as a GFCI, requiring a functioning AC receptacle ground pin will not operate.

Special Requirements

There may be Federal, 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:

This generator is not intended to be used at a construction site or similar activity as defined by NFPA 70-2014 (NEC) section 590.6.

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 or other alternative power sources and must comply with all applicable laws and electrical codes.

WARNING

electrical shock or burn resulting in death or serious injury.

Generator voltage could cause

Portable Generator Location

Before starting the portable generator there are two equally important safety concerns regarding carbon monoxide (CO) poisoning and fire that must be addressed.

Operation Location of Portable Generator to REDUCE THE RISK OF CARBON MONOXIDE POISONING

All fossil fuel burning equipment, such as a portable generator, contains carbon monoxide (CO) gas in the engine exhaust, a poisonous gas that could kill you in minutes. You CANNOT smell it, see it, or taste it. Even if you do not smell exhaust fumes, you could still be exposed to carbon monoxide gas. The following must be completed prior to starting the portable generator engine:

• By law it is required in many states to have a carbon monoxide alarm in operating condition in your home. Install/maintain battery-operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up according to the manufacturer’s instructions. A carbon monoxide alarm is an electronic device that detects hazardous levels of carbon monoxide. When there is a buildup of carbon monoxide, the alarm will alert the occupants by flashing visual indicator light and alarm. Smoke alarms cannot detect carbon monoxide gas.

• Use approved transfer equipment to prevent backfeed by isolating generator from electric utility workers.

• When using generator for backup power, notify utility company.

• 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.

USE OUTDOORS - AVOID CARBON MONOXIDE POISONING

MUFFLER

point away from home

Carbon

Monoxide

Alarm

CARBON MONOXIDE ALARM(S)

Install carbon monoxide alarms inside your home. Without working carbon monoxide alarms, you will not realize you are getting sick and dying from carbon monoxide.

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• Operate this product ONLY outside far away from windows, doors and vents to reduce the risk of carbon monoxide gas from accumulating and potentially being drawn towards occupied spaces.

• Your neighbor(s) home may be exposed to the engine exhaust from your portable generator and must be considered when deciding on a location for the safe operation of your portable generator.

• ALWAYS place this product downwind and point the engine exhaust away from occupied spaces.

If you start to feel sick, dizzy, or weak while using this product, get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

Operation Location of Portable Generator to REDUCE THE RISK OF FIRE

WARNING Exhaust heat/gases could ignite

combustibles, structures or damage fuel tank causing a fire, resulting in death or serious injury.

• Portable generator must be at least 5 feet (1.5 m) from any structure, overhang, trees, windows, doors, any wall opening, shrubs, or vegetation over 12 inches (30.5 cm) in height.

• DO NOT place portable generator under a deck or other type of structure that may confine airflow.

• Smoke alarm(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/ recommendations. Carbon monoxide alarms cannot detect smoke.

• DO NOT place portable generator in manner other than shown.

EXAMPLE OF LOCATION TO

REDUCE THE RISK OF FIRE

5 ft.

(1.5 m) min.

5 ft. (1.5 m) min.

MUFFLER

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Features and Controls

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.

A - Engine Switch — Set this switch to ON (I) before

using recoil starter. Set switch to OFF (0) to switch off engine.

B - Circuit Breaker — The 120 Volt AC, 20A duplex

receptacle is provided with a “push to reset” circuit breaker to protect the generator against electrical overload.

C - 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.

D - Oil Fill Cap/Dipstick — Check and add engine oil

here.

E - Oil Drain Plug — Drain engine oil here. F - Grounding Fastener — Consult your local agency

having jurisdiction for grounding requirements in your area.

G - Spark Arrester Muffler — Exhaust muffler lowers

engine noise and is equipped with a spark arrester screen.

H - Air Cleaner — Protects engine by filtering dust

and debris out of intake air.

J - Choke Lever — Used when starting a cold engine. K - Recoil Starter — Used to start the engine

manually.

L - Fuel Valve — Used to turn fuel supply on and off to

engine.

M - Fuel Tank — Capacity of 1.5 U.S. gallons (5.7 l).

Items Not Shown: Engine Identification — Provides model, type and

code of engine. Please have these readily available if calling for assistance.

Identification Label (on back side of control panel)— Provides model and serial number of generator. Please have these readily available if calling for assistance.

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Cord Sets and Receptacles

Use only high quality, well-insulated, grounded extension cords with the generator’s receptacles. Inspect extension cords before each use.

Check the ratings of all extension cords before you use them. Check the operator’s manuals of devices for the manufacturer’s recommendations.

WARNING Damaged or overloaded electrical

cords could overheat, arc, and burn resulting in death or serious injury.

• ONLY use cords rated for your loads.

• Follow all safeties on electrical cords.

• Inspect cord sets before each use.

120 Volt AC, 20 Amp, Duplex Receptacle

The duplex receptacle is protected against overload by a push to reset circuit breaker.

Use receptacle to operate 120 Volt AC, single–phase, 60 Hz electrical loads requiring up to 1,150 watts (1.15KW) at 9.6 Amps of current.

NOTICE

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 Generator Capacity.

Receptacles may be marked with rating

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Operation

Starting the Engine

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

1. Make sure unit is on a level surface.

NOTICE Failure to start and operate the unit on a level surface could cause the unit not to start or shut down during operation.

2. Turn the fuel valve (A) to ON (I) position.

6. Move choke lever to half choke position, and pull recoil handle twice.

• If engine fails to start, repeat steps 5 thru 7.

7. Slowly move choke lever to RUN position ( engine falters, move choke lever to half choke position until engine runs smoothly, and then to RUN position ( ).

NOTICE If engine floods, place choke lever in RUN position ( ) and crank until engine starts.

NOTICE 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. If so, oil must be at proper level for engine to start.

). If

3. Push choke lever (B) to CHOKE ( ) position.

4. Push engine switch (C) to the ON (I) position.

5. Grasp recoil handle and pull slowly until slight resistance is felt. Then pull rapidly to start engine.

• If engine starts, proceed to step 7.

• If engine fails to start, proceed to step 6.

WARNING Exhaust heat/gases could ignite

combustibles, structures or damage fuel tank causing a fire, resulting in

death or serious injury. Contact with muffler area could cause burns resulting in serious injury.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

Contact the original equipment manufacturer, retailer, or

dealer to obtain a spark arrester designed for the exhaust system installed on this engine.

• Replacement parts must be the same and installed in the same position as the original parts.

WARNING Starter cord kickback (rapid

retraction) will pull hand and arm toward engine faster than you can let go which could cause broken bones, fractures,

bruises, or sprains resulting in serious injury.

• 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.

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Connecting Electrical Loads

1. Let engine stabilize and warm up for a few minutes after starting.

2. Plug in and turn on the desired 120 Volt AC, single phase, 60 Hz electrical loads.

NOTICE

• DO NOT connect 240 Volt loads to the 120 Volt duplex receptacle.

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

• DO NOT connect 50 Hz loads to the generator.

• DO NOT OVERLOAD THE GENERATOR. See Generator Capacity.

NOTICE

capacity could damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage

capacity. See Generator Capacity.

• 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

Low Oil Shutdown

If the engine oil drops below a preset level, an oil

switch will stop the engine or will not allow you to start the engine. Make sure unit is on a level surface and check oil level with dipstick.

If oil level is at FULL mark on dipstick:

1. DO NOT try to restart the engine.

Contact an Authorized Briggs & Stratton Service Dealer.

3. DO NOT operate engine until oil level is corrected.

If oil level is below FULL mark on dipstick:

1. Add oil to bring level to FULL mark.

2. Restart engine and if the engine stops again a low oil condition may still exist. DO NOT try to restart the engine.

3. Contact an Authorized Briggs & Stratton Service Dealer.

4. DO NOT operate engine until oil level is corrected.

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. Push engine switch to the OFF (0) position.

WARNING Fuel and its vapors are extremely

flammable and explosive which could cause burns, fire or explosion resulting in death or serious injury.

• DO NOT stop engine by moving choke handle to CHOKE position

4. Turn fuel valve lever to the OFF (0) position.

( ).

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Generator Capacity

To make sure your generator can supply enough running watts and starting watts for the items you will power at the same time, follow these simple steps:

1. Select the items you will power at the same time. See following list for typical wattages.

Tool or Appliance

Light Bulb - 75 Watt 75 Sump Pump 800 1200

Refrigerator/Freezer 800 2000 Water Well Pump - 1/3 HP 1000 2000 Window AC - 10,000 BTU 1200 1800 Furnace Fan Blower - 1/2 HP 800 1300 Microwave Oven - 1000 Watt 1000 Color Television - 42” 280 -

Personal Computer w/17” monitor 800 Garage Door Opener - 1/2 HP 480 520

* Typical wattages listed are approximate only. Check

tool or appliance for actual wattage.

** Per Briggs & Stratton 628K, Starting Watts

represents the momentary electrical current the generator can provide to start electric motors. Starting Watts does not represent the power required to continuously run electrical loads. Starting Watts is the maximum current that can momentarily be supplied when starting a motor, multiplied by the generator’s rated voltage.

2. Total the running watts. This is the amount of power your generator must produce to keep your items running. See following example:

Running

Watts*

Starting

Watts**

Power Management

To manage generator power, sequentially add loads as follows:

1. With nothing connected to generator, start the engine outdoors.

2. Plug in and turn on the first load, preferably the largest load you have.

3. Permit the generator output to stabilize (engine runs smoothly and attached device operates properly).

4. Plug in and turn on the next load.

5. Again, permit the generator to stabilize.

6. Repeat steps 4 and 5 for each additional load.

Never add more loads than the generator capacity. Take special care to consider surge loads in generator capacity.

Example

Tool or Appliance Running Watts Starting Watts

Window air conditioner Refrigerator 800 2000

Television 280 — Light (75 Watts) 75 —

Total running watts = 2355 Highest starting watts = 2000 Total generator watts required = 4355

3. Estimate the starting watts you will need. Because not all motors start at the same time, total starting wattage can be estimated by adding only the item with the highest additional starting watts requirements to the total running watts from step 2.

1200 1800

2355 Total

Running Watts

2000 Highest

Starting Watts

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Maintenance

Maintenance Schedule

Follow the hourly or calendar intervals, whichever occurs first. More frequent service is required when operating in adverse conditions noted below.

First 5 Hours

• Change engine oil

Every 8 Hours or Daily

• Clean debris

• Check engine oil level

Every 50 Hours or every season

• Clean/Replace air filter

Every 100 Hours or every season

• Change oil

• Change/Adjust spark plug

• Clean spark arrester

• Service fuel valve

1 Service more often under dirty or dusty conditions.

General Recommendations

Regular maintenance will improve the performance and extend the life of the generator. See any authorized dealer for service.

The generator’s warranty does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual.

NOTICE

damage it and shorten its life.

• NEVER operate generator without protective housing or covers to assure proper cooling.

Some adjustments will need to be made periodically to properly maintain your generator.

All service and adjustments should be made at least once each season. A new spark plug and clean air filter assure proper fuel-air mixture and help your engine run better and last longer. Follow the requirements in the Maintenance Schedule chart above.

Emissions Control Maintenance, replacement, or repair of the

emissions control devices and systems may be performed by any non-road engine repair establishment or individual. However, to obtain

”no charge” emissions control service, the work must be performed by a factory authorized dealer. See the Emissions Warranty.

Improper treatment of generator could

Generator Maintenance

Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture, or any corrosive vapors. Cooling air slots in the generator must not become clogged with snow, leaves, or any other foreign material.

NOTICE DO NOT use water or other liquids to clean generator. Liquids can enter engine fuel system, causing poor performance and/or failure to occur. In addition, if liquid enters generator through cooling air slots, some of the liquid will be retained in voids and cracks of the rotor and stator winding insulation. Liquid and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

Cleaning

Daily or before use, look around and underneath the generator for signs of oil or fuel leaks. Clean accumulated debris from inside and outside the generator. Keep the linkage, spring and other engine controls clean. Keep the area around and behind the muffler free from any combustible debris. Inspect cooling air slots and openings on generator. These openings must be kept clean and unobstructed.

Engine parts should be kept clean to reduce the risk of overheating and ignition of accumulated debris:

• Use a damp cloth to wipe exterior surfaces clean.

NOTICE

damage it and shorten its life.

• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• DO NOT insert any objects through cooling slots.

• Use a soft bristle brush to loosen caked on dirt or oil.

• Use a vacuum cleaner to pick up loose dirt and

Improper treatment of generator could

debris.

Fuel Valve Maintenance

The fuel valve is equipped with a fuel sediment cup, screen, and o-ring that need to be cleaned.

1. Move fuel valve to OFF (0) position.

2. Remove sediment cup (A) from fuel valve.

Remove o-ring (B) and screen (C) from fuel valve.

3. Wash sediment cup, o-ring, and screen in a

nonflammable solvent. Dry them thoroughly.

4. Place screen and o-ring into fuel valve. Install

sediment cup and tighten securely.

5. Move fuel valve to ON (I) position, and check for

leaks. Replace fuel valve if there is any leakage.

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Engine Maintenance

WARNING Unintentional sparking could cause

fire or electric shock resulting in death or serious injury.

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.

Oil

Oil Recommendations

We recommend the use of Briggs & Stratton Warranty Certified oils for best performance. Other high-quality detergent oils are acceptable if classified for service SF, SG, SH, SJ or higher. DO NOT use special additives.

Outdoor temperatures determine the proper oil viscosity for the engine. Use the chart to select the best viscosity for the outdoor temperature range expected.

3. Verify oil is at FULL mark (A) on dipstick. Replace

and tighten oil cap/dipstick.

Adding Engine Oil

1. Make sure generator is on a level surface.

2. Check oil level as described in Checking Oil

Level.

3. If needed, slowly pour oil into oil fill opening to the full mark on dipstick. DO NOT overfill.

NOTICE Overfilling with oil could cause the engine to not start, or hard starting.

• DO NOT overfill.

• If over the FULL mark on dipstick, drain oil to reduce oil

level to FULL mark on dipstick.

* Below 40°F (4°C) the use of SAE 30 will result in hard starting. ** Above 80°F (27°C) the use of 10W30 may cause

increased oil consumption. Check oil level more frequently.

Checking Oil Level

Oil level should be checked prior to each use or at least every 8 hours of operation. Keep oil level maintained.

1. Make sure generator is on a level surface.

2. Clean area around oil fill, remove oil cap/dipstick and wipe dipstick with clean cloth. Replace dipstick. Remove and and check oil level.

NOTICE DO NOT screw in dipstick when checking oil level.

4. Replace and tighten oil cap/dipstick.

Changing Engine Oil

If you are using your generator under extremely dirty or dusty conditions, or in extremely hot weather, change the oil more often.

CAUTION Avoid prolonged or repeated skin

contact with used motor oil.

• Used motor oil has been shown to cause skin cancer in certain laboratory animals.

• Thoroughly wash exposed areas with soap and water.

KEEP OUT OF REACH OF CHILDREN.

DON’T POLLUTE. CONSERVE RESOURCES. RETURN USED OIL TO COLLECTION CENTERS.

Change the oil while the engine is still warm from running, as follows:

1. Make sure unit is on a level surface.

2. Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact spark plug.

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3. Clean area around oil drain plug (A). The oil

drain plug is located at base of engine, opposite carburetor.

4. Remove oil drain plug and drain oil completely into a suitable container.

5. Reinstall oil drain plug and tighten securely. Remove oil cap/dipstick.

6. Slowly pour recommended oil (about 11.8 oz. (0.35 l)) into oil fill opening. Pause to permit oil to settle. Fill to FULL mark on dipstick.

7. Wipe dipstick clean each time oil level is checked. DO NOT overfill.

8. Reinstall oil cap/dipstick. Tighten cap securely.

9. Wipe up any spilled oil.

Service Air Cleaner

Your engine will not run properly and may be damaged if you run it with a dirty air cleaner. Clean or replace more often if operating under dusty or dirty conditions.

To service the air cleaner, follow these steps:

1. Loosen the screws (B) that hold the cover (C).

2. Open the cover and remove the filter (D).

3. Wash the foam element in liquid detergent and water. Squeeze dry the foam element in a clean cloth.

4. Saturate the foam element with clean engine oil. To remove the excess engine oil, squeeze the foam element in a clean cloth.

5. Install the filter.

6. Install the air filter cover and tighten the screws.

Service Spark Plug

Changing spark plug will help your engine to start easier and run better.

1. Clean area around spark plug.

2. Remove and inspect spark plug.

3. Replace spark plug if electrodes are pitted, burned or porcelain is cracked. Use the recommended replacement spark plug. See Specifications.

4. Check electrode gap with wire feeler gauge and reset spark plug gap to recommended gap if necessary (see Specifications).

5. Install spark plug and tighten firmly.

Inspect Muffler and Spark Arrester

Inspect the muffler for cracks, corrosion, or other damage. Remove the spark arrester, if equipped, and inspect for damage or carbon blockage. If replacement parts are required, make sure to use only original equipment replacement parts.

WARNING Exhaust heat/gases could ignite

combustibles, structures or damage fuel tank causing a fire, resulting in

death or serious injury. Contact with muffler area could cause burns resulting in serious injury.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

Contact the original equipment manufacturer, retailer, or

dealer to obtain a spark arrester designed for the exhaust system installed on this engine.

• Replacement parts must be the same and installed in the same position as the original parts.

Clean or replace spark arrester as follows:

1. Allow the engine to cool completely before servicing the spark arrester.

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2. Remove the two screws (A) holding the cover plate (B) which retains the end of the spark arrester (C) to the muffler (D).

3. Remove the spark arrester screen.

4. Carefully remove the carbon deposits from the spark arrester screen with a wire brush.

5. Replace the spark arrester if it is damaged.

6. Position the spark arrester in the muffler and attach the cover plate with the two screws.

Storage

The generator should be started at least once every seven days and allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than 30 days, use the following guidelines to prepare it for storage.

Generator Storage

• Clean the generator as outlined in Cleaning.

• Check that cooling air slots and openings on generator are open and unobstructed.

WARNING Fuel and its vapors are extremely

flammable and explosive which could cause burns, fire or explosion resulting in death or serious injury.

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 could ignite fuel vapors.

WHEN DRAINING FUEL

• Turn generator engine OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

• Drain fuel tank outdoors.

• Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.

• Check fuel lines, tank, cap and fittings frequently for cracks or leaks. Replace if necessary.

• Do not light a cigarette or smoke.

Change Engine Oil

While engine is still warm, drain oil from crankcase. Refill with recommended grade. See Changing Engine

Oil.

Other Storage Tips

1. DO NOT store fuel from one season to another unless it has been treated as described in Long Term Storage Instructions.

2. Replace fuel container if it starts to rust. Rust and/ or dirt in fuel can cause problems if it’s used with this unit.

3. Cover unit with a suitable protective cover that does not retain moisture.

WARNING Storage covers could cause a fire

resulting in death or serious injury

Long Term Storage Instructions

Fuel can become stale when stored over 30 days. Stale fuel causes acid and gum deposits to form in the fuel system or on essential carburetor parts. To keep fuel fresh, use Briggs & Stratton® Advanced Formula Fuel Treatment & Stabilizer, available wherever Briggs & Stratton genuine service parts are sold.

There is no need to drain gasoline from the engine if a fuel stabilizer is added according to instructions. Run the engine for 2 minutes to circulate the stabilizer throughout the fuel system before storage.

If gasoline in the engine has not been treated with a fuel stabilizer, it must be drained into an approved container. Run the engine until it stops from lack of fuel. The use of a fuel stabilizer in the storage container is recommended to maintain freshness.

• DO NOT place a storage cover over a hot generator.

• Let equipment cool for a sufficient time before placing the cover on the equipment.

4. Store generator in clean, dry area.

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Troubleshooting

Problem Cause Correction

Engine is running, but no AC output is available.

Engine runs good at no-load but“bogs down” when loads are connected.

Engine will not start, starts and runs rough or shuts down when running.

Engine lacks power.

Engine “hunts” or falters.

1. One of the circuit breakers is open.

2. Fault in generator.

3. Poor connection or defective cord set.

4. Connected device is bad.

1. Short circuit in a connected load.

2. Engine speed is too slow.

3. Generator is overloaded.

4. Shorted generator circuit.

5. Clogged or dirty fuel filter.

1. Engine rocker switch set to OFF (0) position.

2. Fuel Valve is in OFF (0) position.

3. Low oil level.

4. Dirty air cleaner.

5. Clogged or dirty fuel filter.

6. Out of fuel.

7. Stale fuel.

8. Spark plug wire not connected to spark plug.

9. Bad spark plug.

10. Water in fuel.

11. Flooded.

12. Excessively rich fuel mixture.

13. Intake valve stuck open or closed.

14. Engine has lost compression.

1. Load is too high.

2. Dirty air filter.

3. Clogged or dirty fuel filter.

1. Carburetor is running too rich or too lean.

2. Clogged or dirty fuel filter.

1. Reset circuit breaker.

2. Contact authorized service facility.

3. Check and repair.

4. Connect another device that is in good condition.

1. Disconnect shorted electrical load.

2. Contact authorized service facility.

3. See Generator Capacity.

4. Contact authorized service facility.

5. Clean or replace fuel filter.

1. Set engine rocker switch to ON (I) position.

2. Turn fuel valve to ON (I) position.

3. Fill crankcase to proper level or place generator on level surface.

4. Clean or replace air cleaner.

5. Clogged or dirty fuel filter.

6. Fill fuel tank.

7. Drain fuel tank and carburetor; fill with fresh fuel.

8. Connect wire to spark plug.

9. Replace spark plug.

10. Drain gas tank and carburetor; fill with fresh fuel.

11. Wait 5 minutes and re-crank engine.

12. Contact authorized service facility.

13. Contact authorized service facility.

14. Contact authorized service facility.

1. See Generator Capacity.

2. Replace air filter.

3. Clean or replace fuel filter.

1. Contact authorized service facility.

2. Clean or replace fuel filter.

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Schematic

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BRIGGS & STRATTON PRODUCTS WARRANTY POLICY January 2014

Limited Warranty

Briggs & Stratton warrants that, during the warranty period specified below, it will repair or replace, free of charge, any part that is defective in material or workmanship or both. Transportation charges on product submitted for repair or replacement under this warranty must be borne by purchaser. This warranty is effective for and is subject to the time periods and conditions stated below. For warranty service, find the nearest Authorized Service Dealer in our dealer locator map at www.briggsandstratton.com. The purchaser must contact the Authorized Service Dealer, and then make the product available to the Authorized Service Dealer for inspection and testing.

There is no other express warranty. Implied warranties, including those of merchantability and fitness for a particular purpose, are limited to the warranty period listed below, or to the extent permitted by law. Liability for incidental or consequential damages are excluded to the extent exclusion is

permitted by law. Some states or countries do not allow limitations on how long an implied warranty lasts, and some states or countries do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state or country to country.**

WARRANTY PERIOD

Consumer Use Commercial Use

24 months ▲ None

▲ After 12 months, warranty covers parts only. Battery (if equipped) 3 months consumer use, none commercial use.

** In Australia - Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. For warranty service, find the nearest Authorized Service Dealer in our dealer locator map at BRIGGSandSTRATTON.COM, or by calling 1300 274 447, or by emailing or writing to salesenquires@briggsandstratton.com.au, Briggs & Stratton Australia Pty Ltd, 1 Moorebank Avenue, NSW, Australia, 2170.

The warranty period begins on the date of purchase by the first retail or commercial consumer. “Consumer use” means personal residential household use by a retail consumer. “Commercial use” means all other uses, including use for commercial, income producing or rental purposes. Once a product has experienced commercial use, it shall thereafter be considered as a commercial use product for purposes of this warranty.

Save your proof of purchase receipt. If you do not provide proof of the initial purchase date at the time warranty service is requested, the manufacturing date of the product will be used to determine the warranty period. Product registration is not required to obtain warranty service on Briggs & Stratton products.

ABOUT YOUR WARRANTY

Warranty service is available only through Briggs & Stratton Authorized Service Dealers. Most warranty repairs are handled routinely, but sometimes requests for warranty service may not be appropriate. This warranty covers only defects in materials or workmanship. It does not cover damage caused by improper use or abuse, improper maintenance or repair, normal wear and tear, or stale or unapproved fuel.

Improper Use and Abuse - The proper, intended use of this product is described in the Operator’s Manual. Using the product in a way not described in the Operator’s Manual or using the product after it has been damaged will not be covered under this warranty. Warranty coverage will also not be provided if the serial number on the product has been removed or the product has been altered or modified in any way, or if the product has evidence of abuse such as impact damage or water/chemical corrosion damage.

Improper Maintenance or Repair - This product must be maintained according to the procedures and schedules provided in the Operator’s Manual, and serviced or repaired using genuine Briggs & Stratton parts or equivalent. Damage caused by lack of maintenance or use of non-original parts is not covered by warranty.

Normal Wear and Tear - Like most mechanical devices, your unit is subject to wear even when properly maintained. This warranty does not cover repairs when normal use has exhausted the life of a part or the equipment. Maintenance and wear items such as filters, belts, cutting blades, and brake pads (except engine brake pads) are not covered by warranty due to wear characteristics alone, unless the cause is due to defects in material or workmanship.

Stale or Unapproved Fuel - In order to function correctly, this product requires fresh fuel that conforms to the criteria specified in the Operator’s Manual. Engine or equipment damage caused by stale fuel or the use of unapproved fuels (such as E15 or E85 ethanol blends) is not covered by warranty.

Other Exclusions - This warranty excludes damage due to accident, abuse, modifications, alterations, improper servicing, freezing or chemical deterioration. Attachments or accessories that were not originally packaged with the product are also excluded. There is no warranty coverage on equipment used for primary power in place of utility power or on equipment used in life support applications. This warranty does not include used, reconditioned, second-hand, or demonstration equipment or engines. This warranty also excludes failures due to acts of God and other force majeure events beyond the manufacturer’s control.

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

MILWAUKEE, WI, USA

80007708EN (Rev. A)

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PowerBoss 030665-01, 030666-02 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual