Simplicity PORTABLE GENERATOR, POWERBOSS 2500/3500 WATT MODELS 030666-00, 030667-00 Manuel utilisateur

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BRIGGS & STRATTON CORPORATION

MILWAUKEE, WISCONSIN, U.S.A.

Manual No. 80013241 Revision B

Portable Generator

Operator’s Manual

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

Generators and PGMA (Portable Generator Manufacturers’ Association) standard ANSI/PGMA G300-2015, Safety and

Performance of Portable Generators.

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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.

POWERBOSS is a registered trademark of

Briggs & Stratton Corporation.

Generator

Model Number _____________________________

Revision __________________________________

Serial Number ______________________________

Date Purchased ___________________________

Engine

Model Number _____________________________

Type Number ______________________________

Code Number ______________________________

Table of Contents

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

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

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

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

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

Troubleshooting ................................................21

Warranty ......................................................24

Product Specifications ...........................................28

Common Service Parts ..........................................28

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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.

NOTICE

Exceeding generators wattage/amperage

capacity could damage generator and/or electrical

devices connected to it.

• DO NOT exceed the generator’s wattage/amperage

capacity. See Generator Capacity in the Operation section.

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.

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.

Safety Symbols and Meanings

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

indicates information

considered important, but not hazard-related.

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

Indicates information considered important, but

not hazard-related.

Fire

Explosion

Toxic Fumes

Hot Surface

Moving Parts

Electrical Shock

Kickback

Flying Objects

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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.

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 partially-

enclosed 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 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 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

This product can expose you to

chemicals including gasoline engine exhaust, which is

known to the State of California to cause cancer, and

carbon monoxide, which is known to the State of California

to cause birth defects or other reproductive harm. For more

information go to www.P65Warnings.ca.gov.

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NOTICE

Exceeding generators wattage/amperage

capacity could damage generator and/or electrical

devices connected to it.

• DO NOT exceed the generator’s wattage/amperage

capacity. See Generator Capacity in the Operation section.

• 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

Improper treatment of generator could

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.

WARNING Starter and other rotating parts

could entangle hands, hair, clothing, or

accessories resulting in serious injury.

• 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.

WARNING

Generator voltage could cause

electrical shock or burn resulting in death or

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.

• 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 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 forest-

covered, 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.

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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.

4. Leave generator on carton to install wheel kit.

The generator is supplied with:

• Operator’s manual

• Engine oil bottle

NOTICE Be sure you have attached wheels and

support leg (if equipped) prior to adding oil and fuel.

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.

NOTICE

Improper treatment of generator could

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.

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.

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).

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.

3. Install fuel cap and let any spilled fuel evaporate

before starting engine.

High Altitude

At altitudes over 5,000 feet (1524 meters), 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 feet (762 meters) with

the high altitude kit is not recommended.

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).

FUEL

TANK

D

C

B

A

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.

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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 or other alternative power sources and must

comply with all applicable laws and electrical codes.

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 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 CO alarm is an

electronic device that detects hazardous levels of

CO. When there is a buildup of CO, the alarm will

alert the occupants by flashing visual indicator light

and alarm. Smoke alarms cannot detect CO gas.

WARNING

Generator voltage could cause

electrical shock or burn resulting in death or

serious injury.

• Use approved transfer equipment to prevent backfeed by

isolating generator from electric utility workers.

• When using generator for backup power, notify utility

company.

• 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.

Carbon

Monoxide

Alarm

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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.

• DO NOT run this product inside homes, garages,

basements, crawlspaces, sheds, or other partially-

enclosed 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.

• 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.

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.

CARBON MONOXIDE ALARM(S)

USE OUTDOORS - AVOID CARBON MONOXIDE POISONING

point away

from home

MUFFLER

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 - 120 Volt AC, 30 Amp RV Outlet (3500 Watt only)

— May be used to supply electrical power for the

operation of 120 Volt AC, 30 Amp, single phase, 60

Hz electrical, travel trailer loads.

C - Main Breaker (3500 Watt only) — The receptacles

are provided with a main breaker to protect the

generator against electrical overload.

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

here.

E - Oil Drain Plug — Drain engine oil here.

F - 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.

G - Circuit Breakers — The 120 Volt AC, 20A duplex

receptacles are provided with “push to reset” circuit

breakers to protect the generator against electrical

overload.

H - Grounding Fastener — Consult your local agency

having jurisdiction for grounding requirements in

your area.

J - Spark Arrester Muffler — Exhaust muffler lowers

engine noise and is equipped with a spark arrester

screen.

K - Air Cleaner — Protects engine by filtering dust

and debris out of intake air.

L - Choke Lever — Used when starting a cold engine.

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

engine.

N - Recoil Starter — Used to start the engine manually.

P - Fuel Tank — Capacity of 3 U.S. gallons (11.4 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.

G

L

H

M

C

B

A

P

N

D

E

F

K

J

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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 operator’s manuals of devices to be

powered for the manufacturer’s recommendations.

120 Volt AC, 30 Amp RV Outlet (3500 Watt only)

Use a NEMA TT–30 plug with this receptacle. Connect

a 3–wire travel trailer cord set rated for 125 Volt AC

loads at 30 Amps to the plug.

Hot

120V

Ground

(Green)

NEMA

TT-30

Neutral

Use this receptacle to operate 120 Volt AC, 60 Hz,

single phase travel trailer loads requiring up to 3,500

watts (3.5 kW) of power at 29.1 Amps. The outlet is

protected by a push-to-reset circuit breaker.

NOTICE

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 Generator Capacity.

120 Volt AC, 20 Amp, Duplex Receptacles

The duplex receptacles are 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 2,400 watts

(2.4KW) at 20 Amps of current. Use cord sets that are

rated for 125 Volt AC loads at 20 Amps (or greater).

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.

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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.

A

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.

6. Move choke lever to 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 (

). If

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.

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 When plugging into the 120 Volt duplex

receptacles, plug items to be powered in sequence as

shown (3500 Watt ONLY).

NOTICE

• 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

Generator Capacity.

C

B

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 forest-

covered, 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 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.

1

3

2

4

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NOTICE

Exceeding generators wattage/amperage

capacity could damage generator and/or electrical devices

connected to it.

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

See Generator Capacity in the Operation section.

• 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.

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.

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

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.

2.

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.

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

( ).

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15

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.

* 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:

Example

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.

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.

Tool or Appliance

Running

Watts*

Starting

Watts**

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

Tool or Appliance Running

Watts

Starting Watts

Window air conditioner

1200 1800

Refrigerator 800 2000

Television 280 —

Light (75 Watts) 75 —

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

1

Every 100 Hours or every season

• Change oil

1

• 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

Improper treatment of generator could

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.

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

Improper treatment of generator could

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

debris.

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17

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.

A

B

C

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.

Engine Maintenance

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.

* 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 check oil level.

NOTICE DO NOT screw in dipstick when checking oil

level.

3. Verify oil is at full mark (D) on dipstick. Replace

and tighten oil cap/dipstick.

D

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.

4. Replace and tighten oil cap/dipstick.

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.

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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.

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.

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 20 oz.

(0.6 l)) into oil fill opening. Pause to permit oil to

settle. Fill to the 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 Filter

Your engine will not run properly and may be damaged

if you run it with a dirty air filter. Clean or replace more

often if operating under dusty or dirty conditions.

To service the air filter, follow these steps:

1. Unclamp latches (B) that hold on the cover (C).

2. Remove cover and foam air filter (D).

3. Wash the foam air filter in liquid detergent and

water. Squeeze dry the foam air filter in a clean

cloth.

4. Saturate the foam air filter with clean engine oil.

To remove the excess engine oil, squeeze the

ffoam air filter in a clean cloth.

5. Reinstall clean or new foam air filter (D).

6. Reinstall the air filter cover and clamp latches.

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.

B

C

D

B

A

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.

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19

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.

Clean or replace spark arrester as follows:

1. Allow the engine to cool completely before

servicing the spark arrester.

2. Remove the two screws (A) holding the cover plate

(B) which retains the end of the spark arrester (B)

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.

A

D

B

C

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 forest-

covered, 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.

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20 www.powerboss-equipment.com

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.

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

hroughout 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.

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.

4. Store generator in clean, dry area.

WARNING Storage covers could cause a fire

resulting in death or serious injury

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

• Let equipment cool for a sufficient time before placing the

cover on the equipment.

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.

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Simplicity PORTABLE GENERATOR, POWERBOSS 2500/3500 WATT MODELS 030666-00, 030667-00 Manuel utilisateur

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