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POWERSMART SERIES™ INVERTER GENERATOR
SERVICE AND REPAIR MANUAL
MODEL 030473
This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2
No. 100-04 (motors and generators)
279957GS Rev. -
Not
for
Reproduction
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Briggs & Stratton Power Products Group, LLC P.O. Box 702 Milwaukee, WI 53201-0702 Copyright © 2010. All rights reserved. No part of this material may be reproduced or transmitted in any form without the express written permission of Briggs & Stratton Power Products Group, LLC. 2 BRIGGSandSTRATTON.COM Not for Reproduction
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Table of Contents Important Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . 4 Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rewind Starter Replacement . .
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Important Safety Instructions SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. Safety Symbols and Meanings Toxic Fumes Kickback Electrical Shock Fire Explosion Read Manual WARNING Running engine gives off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide could result in death, serious injury, headache, fatigue, dizziness, Moving Parts Flying Objects
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WARNING Generator voltage could cause electrical WARNING Fuel and its vapors are extremely flammable shock or burn resulting in death or serious injury. and explosive which could cause burns, Use approved transfer equipment to prevent fire, or explosion resulting in death, serious backfeed bt isolating generator from electric utility injury, and/or property damage. workers. • When using generator for backup power, notify When Adding or Draining Fuel utility company. • Turn generator en
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NOTICE Exceeding generators wattage/amperage WARNING Unintentional sparking could cause fire or capacity could damage generator and/or electrical devices electric shock resulting in death or serious connected to it. injury. • DO NOT exceed the generator’s wattage/amperage capacity. See Don’t Overload Generator in the Operator’s When Adjusting Or Making Repairs To Your Generator Manual. • Disconnect the spark pluh wire from the spark plug and • Start generator and let engine stabilize be
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Fuel Recommendations Generator Location Fuel must meet these requirements: WARNING Exhaust heat/gases could ignite combustibles • Clean. fresh, unleaded gasoline or structures resulting in death, serious injury and/or property damage. • A minimum of 87 octane/87 AKI (91 RON) • Gasoline with up to 10% ethanol (gasohol) or up to 15%MTBE (methyl tertiary butyl ether) is acceptable. • Keep at least 5 feet (152 cm) of clearance on all sides of generator including overhead. NOTICE: Do not use un
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Fuel Tank Cap Vent Lever Grounding Fastener The fuel tank cap is provided with a vent lever (A, Figure 2) to The generator neutral is floating, which means that the AC seal the fuel tank. The vent lever must be in the “ON” position stator winding is isolated from the grounding fastener and for the engine to run. the AC receptacle ground pins. Therefore, the AC receptacle ground pins are not functional and electrical devices, such as a GFCI will not operate. A Figure 2 When the engine is not
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Generator Components A B C R D P E F N G M L H K J A - Fuel Tank Cap Vent Lever — Turn the vent lever to the L - Overload Alarm — A red LED light comes on and “ON” position when operating the generator. Turn to the cuts power to the receptacles when the generator is “OFF” position when not in use. overloaded. B - Fuel Tank — Capacity of 1.0 U.S. gallon (3.7L). M - Low Oil Indicator — A yellow LED light comes on when the oil in the generator drops below a preset level. C - Choke Lever — U
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Generator Maintenance Maintenance Generator maintenance consists of keeping the unit clean Maintenance Schedule and dry. Operate and store the unit in a clean and dry Follow the hourly or calendar interval, whichever occurs first. environment where it will not be exposed to excessive dust, More frequent service is required when operating in adverse dirt, moisture, or any corrosive vapors. Cooling air slots in conditions noted below. the generator must not become clogged with snow, leaves,
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Engine Maintenance Checking Oil Level / Adding Oil WARNING Unintentional sparking could cause fire or Oil level should be checked prior to each use or at least every electric shock resulting in death or serious 8 hours of operation. Keep oil level maintained. injury. 1. Make sure generator is on a level surface. 2. Loosen the side maintenance cover screws and remove When Adjusting Or Making Repairs To The Generator the side maintenance cover (Figure 4). • Disconnect the spark plug wire from
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Changing Engine Oil Service Air Cleaner If the generator is used under extremely dirty or dusty The engine will not run properly and may be damaged if it is conditions, or in extremely hot weather, change the oil more run with a dirty air cleaner. Service more often if operating often. under dirty or dusty conditions. CAUTION Avoid prolonged or repeated skin contact 1. Loosen the side maintenance cover screws and remove with used motor oil. the side maintenance cover. • Used motor oil has
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Service Spark Plug 4. Remove spark plug and inspect for pitting, corosion, cracks, or other signs of damage. 1. Loosen the four handle screws and remove the handle (Figure 8). 5. Check electrode gap with wire feeler gauge (A, Figure 10) and reset the spark plug gap to recommended gap if necessary. Figure 8 Figure 10 2. Remove the top maintenance cover. 6. Replace spark plug if electrodes are pitted, burned, or 3. Clean area around spark plug and remove spark plug porcelain is cracked. Use t
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Inspect Muffler and Spark Arrester 2. Remove screw (Figure 12) that attaches spark arrester screen muffler. Remove spark arrester screen. Inspect the muffler for cracks, corrosion, or other damage. Remove the spark arrester, if equipped, and inspect for damage or carbon blockage. WARNING Exhaust heat/gases could ignite combustibles or structures resulting in death, serious injury and/or property damage. Contact with muffler area could cause burns resulting in serious injury. • DO NOT tou
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Rewind Starter Replacement 4. Pull out rope from rewind starter as far as it will go. Disassemble Rewind Starter Then allow rope to retract slightly until the hole in the 1. Remove control panel, inverter, and fuel tank as pulley and eyelet in the housing are lined up. Securely described in the Troubleshooting section. clamp the pulley and housing together to prevent the 2. Locate the rewind starter handle (A, Figure 13) and pulley from spinning. remove the screw that is located under the
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Figure 15 Inspect Rewind Starter Parts Assemble Rewind Starter 1. Inspect the pulley for wear, cracks, rough edges, or 1. Install pulley and spring assembly into starter housing. burrs in the rope groove and look for wear in the center Rotate pulley clockwise until slight resistance is felt, hole. If wear or damage is found, replace the pulley and which indicates that the spring has engaged in the spring assembly. anchor tab. 2. Inspect the spring for broken ends, kinks, or burrs. 2. Install
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Troubleshooting Fuel Tank Fuel System The fuel tank is metal (A, Figure 17) and is not repairable. Fuel Pump Inspect tank for: The fuel pump (A, Figure 16) is located on inside of cover. • Corrosion It is operated by vacuum pulses from the engine. The fuel • Leaks pump is not serviceable. If the pump does not operate after If leaks or other damage are found, replace the tank. inspection, replace the pump. Inspect pump for: • Ensure vacuum hose is connected properly • Restrictions or leaks i
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Fuel Valve 3. Check the fuel valve for leaks (C, Figure 21). The fuel valve is mounted behind the side maintenance cover. Check the valve for proper operation as follows: 1. Using small, flat-head screwdriver, pry off cover to the fuel valve knob (Figure 19). C Figure 21 If the fuel valve leaks, it must be replaced as follows: 1. Loosen four screws (Figure 22) on the control panel. Figure 19 2. Remove screw under the cover to remove the knob (B, Figure 20). Figure 22 B Figure 20 18 BRIGG
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2. Remove control panel from enclosure and, without 5. Locate fuel valve (F, Figure 25) inside of the generator disconnecting wiring, set control panel aside (D, Figure 23). enclosure. 3. Remove inverter from enclosure (E) and, without 6. Remove hoses (G) and loosen screw (H) to remove the disconnecting wiring, set inverter assembly aside. fuel valve. 7. Install a new fuel valve using the above steps in reverse order. E H F G D Figure 23 Figure 25 4. Close vent on fuel cap. Carefully spread e
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Carburetor 3. Remove screw from air filter cover (Figure 28). Set cover aside. Inspect carburetor for: • Blockage • Leaks • Varnish or Gummy Residue If carburetor is suspected to have a fuel leak or blockage, follow these steps: 1. Loosen the two self-locking screws and remove the side maintenance cover (Figure 26) and set aside. This will expose the air filter and carburetor assemblies. Figure 28 4. Remove breather filter (B, Figure 29) to expose the air cleaner assembly screw. Loosen and
