Briggs & Stratton Powerlink On-Board Generator System Owner's manual

SEVERING OF FINGERS indicates a hazard which, if not
avoided, could result in death, or serious injury.
SEVERING OF HANDS, OR FINGERS indicates a
hazard which, if not avoided, could result in death, or
serious injury.
TOXIC FUMES indicates a hazard which, if not avoided,
could result in death, serious injury, and/or property
damage.
HOT SURFACE indicates a hazard which, if not avoided,
could result in death, serious injury, and/or property
damage.
FIRE indicates a hazard which, if not avoided, could
result in death, serious injury, and/or property da-
mage.
SHOCK indicates a hazard which, if not avoided, could
result in death, serious injury, and/or property dam-
age.
Read and follow all Safety Information and Instructions
before first use of this product. Keep these instructions for
future reference.
The POWERLINKEOperating Instructions
contain safety information to:
•Make you aware of hazards associated with the
POWERLINKOn-Board Generator System.
•Inform you of the risk of injury associated with those
hazards, and
•Tell you how to avoid or reduce the risk of injury.
Failure to follow instructions could result in serious injury
or death. The safety alert symbol is used to identify safety
information about hazards which can result in death,
serious injury, and/or property damage.
This document is a supplement
to the Operating & Maintenance
Instructions for the engine that
powers this on-board generator.
CAUTION, when used without the alert symbol, indicates
a situation that could result in damage to the engine.
CAUTION indicates a hazard which, if not avoided, might
result in minor or moderate injury.
WARNING indicates a hazard which, if not avoided, could
result in death or serious injury.
DANGER indicates a hazard which, if not avoided, will
result in death or serious injury.
PRINTED IN U.S.A. Copyright 2004 by Briggs & Stratton Corporation FORM NO. 275214-1/04
This POWERLINKsystem includes the engine, an inverter,
and a Ground Fault Circuit Interrupter (GFCI). The GFCI is a
receptacle which protects against electrical shocks. A GFCI
detects ground faults.
If a ground fault is detected, the GFCI will interrupt the circuit
when it detects a difference in electric current. One type of
ground fault occurs when electricity flows through a person to
an earth ground instead of following the normal safe path.
Please be aware that the GFCI is not fail proof. Most brands are
susceptible to failures from power surges such as nearby
lightening strikes. For this reason and for your protection,
Briggs & Stratton makes the recommendation that the GFCI
gets tested before every use of the POWERLINKsystem. If
found to be defective, it must be replaced by an Authorized
Service Dealer before further use.
Also, please note that the GFCI does not protect from serious
electrical shocks resulting from contact between the system
neutral (white wire) and the “hot lead” (black wire). See listed
warnings within this document for further clarification on
hazards and how to avoid them.
Need assistance?
Go to www.briggsandstratton.com
for information.
Or call, 1-800-233-3723, (U.S.A. and Canada)
to hear a menu of pre-recorded messages
offering engine maintenance information.

These labels warn of potential hazards that can result in death or serious injury.
Read and understand them before operating the equipment.
WARNING
An Authorized Service Dealer should perform all service.
Improper maintenance or repair could result in death,
serious injury and/or property damage.
Do not perform any maintenance on the POWERLINK
On-Board Generator System with the engine running. Stop
the engine and remove the spark plug wires from the spark
plugs.
Do not perform any modifications to the POWERLINK
On-Board Generator System, the inverter, or the GFCI
receptacle.
Do not remove cover on the GFCI receptacle.
The GFCI receptacle must be serviced with original factory
approved GFCI receptacle, and which conforms to N.E.C.
requirements. See listing under Service and Maintenance.
Never tamper with engine governed speed.
WARNING
Improper operation could result in death, serious injury and/or
property damage.
Never use unit as a backup alternative for a main power source.
GFCI receptacle will not protect you against:
•Line-to-line shocks (like the kind you get by touching
metal in both straight slots of a receptacle)
•Current overloads
•Line-to-line short circuits
Never connect the POWERLINKOn-Board Generator
System to the electrical system of a building. Doing so could
cause a power back feed that may electrocute utility workers or
others who come in contact with the line.
Never operate without the factory installed GFCI receptacle.

WARNING
The POWERLINKOn-Board Generator System produces
electricity that could result in death, serious injury and/or
property damage if proper precautions are not followed.
Maintain and use proper sized electrical cord sets and exten-
sion cords per electrical device specification. Use cords rated
for no less than 15 amps.
Use cords which are in good condition. Never use worn, bare,
frayed or otherwise damaged cord sets.
Avoid contact with bare wires, terminals, and damaged cords.
Keep extension cord lengths at minimum possible length. Long
extension cords draw additional power.
Do not operate unit:
•in rain.
•if electrical cord or device, which is plugged into the GFCI
receptacle over heats.
•if electrical output is lost.
•if flame, spark or smoke is observed while unit is running.
Never handle any kind of electrical cord or device while
standing in water, or while barefoot, or while hands and/or feet
are wet.
Running the POWERLINKOn-Board Generator System
produces heat.
Severe thermal burns can occur on contact.
WARNING
Avoid contact with hot surfaces, such as the inverter.
DANGER
The engine used in the POWERLINKOn-Board
Generator System gives off carbon monoxide, an odorless,
colorless, and poisonous gas.
Breathing carbon monoxide can cause nausea, fainting, or
death.
Never run POWERLINKOn-Board Generator System in an
enclosed area, even if doors or windows are open.
THE POWER IN POWERLINK
The POWERLINKOn-Board Generator System will operate
continuously at 1000 watts output, and up to 1500 watts for brief
periods. Operating at loads above 1000 watts continuously may
trigger the POWERLINKsystem to reset and halt the electrical
output needed to power the load. The system produces 120 volts, 60
cycle AC electrical power. Prior to connecting any electrical device,
ensure compatibility of operating voltage and frequency
requirement.
The POWERLINKsystem output remains 120 volts throughout the
entire engine speed range. Output wattage increases with engine
speed. Select the engine speed that will power the electrical device
satisfactorily without triggering the POWERLINK reset.
CAUTION: Damage may result if the equipment
operates outside of a +/–10% voltage variation from the
rated voltage of 120V.
POWERLINKOPERATING
INSTRUCTIONS
[1] Start the engine and set the desired engine speed.
[2] No load should be applied to the engine, (Power-Take-Off
should be disengaged) and the parking brake must be
LOCKED. If these are not done, the POWERLINKsystem
will not operate.
[3] Actuate the POWERLINKreset switch. Move the reset
switch to the OFF position and then return it to the ON position.
[4] Plug the electrical device into the GFCI receptacle and start
device. See also, Applying Device Load.
[5] Any time the engine stops, for any reason, the POWERLINK
reset switch must be actuated. Follow the steps outlined
above. See also, Electrical Operating Power Loss.

Applying Device Load
The electrical device requiring power should not exceed the capacity
of the POWERLINKsystem (See The Power in POWERLINK). It
is recommended that all electrical devices and extension cords
plugged into the GFCI receptacle have a three prong terminal. If
using more than one electrical device, plug-in and start the higher
rated load first.
WARNING Unintentional start-up can result in
entanglement, traumatic
amputation, or laceration.
•Always ensure the device being plugged into the system is
OFF before connecting it to the GFCI receptacle.
•Check device being connected for bare wires, or frayed
electrical cords.
Types of products (requiring 1500 watts or less*) that could be
powered by the POWERLINKsystem:
Hedge trimmer Circular saw Lighting
Refrigerator Furnace Blower Freezer
Hand tools Chain saw String trimmer
Television Sump pump Edger
Radio Computer
*Always confirm the product’s power rating before plugging into the
POWERLINKsystem.
CAUTION: Do not connect a battery charger, or charge
batteries from POWERLINK. This could cause
damage to the battery charger or the POWERLINK
system.
Electrical Operating Power Loss
The POWERLINKsystem has safety features to protect the
system and the operator. The electrical output of the POWERLINK
system will shut down at any electrical overload caused by
temperature or a system overload.
On an overload, the reset opens and disconnects electrical power to
the GFCI receptacle, tripping the system. A manual reset switch,
located on the tractor, has been installed to reset the electrical output
of the POWERLINKsystem. Once reset, operating power is
returned and the work load can be reconnected.
If the system continually trips, causing the operator to reset,
increase engine speed. If engine is running at top speed and the
system is still tripping, the system is being overloaded. Decrease the
load.
If power does not resume after reset, it may be a thermal overload.
Wait 15 minutes before actuating the reset.
The electrical operating output will also cease if there is a ground
fault. The GFCI receptacle will trip to protect the operator. See also,
Resetting the POWERLINK System.
Do not perform any modifications to
the POWERLINKOn-Board
Generator System, the inverter, or
the GFCI receptacle.
Never tamper with engine governed
speed.
WARNING
Resetting the POWERLINKESystem
[1] Turn off any device or appliance that was in use prior to the loss
of electrical operating power.
[2] Verify if the RESET button on GFCI receptacle has not been
tripped.
Note: The RESET button will pop out if tripped. To
restore, press the RESET button.
[3] The engine must be running and the parking brake must be set.
[4] Actuate the POWERLINKreset switch. Move the reset
switch to the OFF position and then return it to the ON position.
For the operators safety, there is a two second delay in power
to the GFCI receptacle after reset.
TESTING THE GFCI
To ensure proper operation, and avoid injury the GFCI receptacle
should be tested before every use.
[1] Have the POWERLINKsystem running and the power reset.
[2] Plug in a lamp or radio for verification that electrical power is
present.
[3] Press the GFCI TEST button in order to trip the system and
stop the flow of electricity.
[4] If the device is still being powered, the GFCI is not working
properly. Seek an Authorized Service Dealer.
[5] If the power goes off, the GFCI is working properly. To restore
power, press the RESET button.
SERVICE AND MAINTENANCE OF
POWERLINKSYSTEM
Repairs to the POWERLINK
system and wiring must be done by
an Authorized Service Dealer. All
electrical components and wiring
must be in the original position when
the repair is complete.
The GFCI must be replaced with the appropriate parts listed in UL
Standard 943, Class A and conforming to N.E.C. requirements.
Units built before an engine date code of 040201 must be
replaced with Eagle GFCI p/n GF15BK (B&S p/n 699146).
Units built after an engine date code of 040131 must be replaced
with Hubbell/Bryant GFCI p/n GF53BKA (B&S p/n 790239).
WARNING
Care must be exercised when
removing and installing the engine
flywheel. The force of the flywheel
magnets is extremely high and they
will rapidly draw the flywheel to the
engine. Hand and/or finger injury can
result. A lift must be used to remove and install the flywheel.
Always consult an Authorized Briggs & Stratton Service Dealer on
the service of this engine.
WARNING