Generac Power Systems 5500EXL User manual

Portable Generator Owner’s Manual
Questions? Help is just a moment away!
Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com
Model No. 1642-2 (5,500 Watt AC Generator) Manual No. 189439GS Revision 1 (10/15/2002)

2
PowerBoss 5,500 Watt Storm-Plus Generator
EQUIPMENT
DESCRIPTION
Read this manual carefully and become
familiar with your pressure washer. Know its
applications, its limitations and any hazards
involved.
This generator is an engine–driven, revolving field, alternating
current (AC) generator. It was designed to supply electrical
power for operating compatible electrical lighting, appliances,
tools and motor loads.The generator’s revolving field is
driven at about 3,600 rpm by a single-cylinder engine.
CAUTION! DO NOT exceed the generator’s
wattage/amperage capacity. See “Don’t Overload the
Generator” on page 10.
Every effort has been made to ensure that information in this
manual is accurate and current. However, Generac reserves
the right to change, alter or otherwise improve the product
and this document at any time without prior notice.
The Emission Control System for this generator is warranted
for standards set by the Environmental Protection Agency. For
warranty information refer to the engine owner’s manual.
SAFETY RULES
The safety alert symbol ( ) is used with a signal word
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety message to alert you to hazards. DANGER indicates
a hazard which, if not avoided, will result in death or serious
injury. WARNING indicates a hazard which, if not avoided,
could result in death or serious injury. CAUTION
indicates a hazard which, if not avoided, might result in
minor or moderate injury. CAUTION, when used
without the alert symbol, indicates a situation that could
result in equipment damage. Follow safety messages to
avoid or reduce the risk of injury or death.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
In the State of California a spark arrester is required by law
(Section 4442 of the California Public Resources Code).
Other states may have similar laws. Federal laws apply on
federal lands. If you equip the muffler with a spark arrester,
it must be maintained in effective working order.
• Operate generator ONLY outdoors.
• Keep at least 2 feet of clearance on all sides of generator for
adequate ventilation.
• DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide will cause nausea,
fainting or death.
DANGER
• When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
• Use a ground circuit fault 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.
• DO NOT handle generator or electrical cords while standing
in water, while barefoot, or while hands or feet are wet.
• DO NOT allow unqualified persons or children to operate or
service generator.
Generator produces powerful voltage.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
DANGER
• National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.
Failure to properly ground generator can result
in electrocution, especially if the generator is
equipped with a wheel kit.
DANGER
WHEN ADJUSTING OR MAKING REPAIRS TOYOUR
GENERATOR
• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
Unintentional sparking can result in fire or
electric shock.
WARNING

PowerBoss 5,500 Watt Storm-Plus Generator
3
WHEN ADDING FUEL
• Turn generator OFF and let it cool at least 2 minutes before
removing gas cap. Loosen cap slowly to relieve pressure in tank.
• Fill fuel tank outdoors.
• DO NOT overfill tank.Allow space for fuel expansion.
• Keep gasoline away from sparks, open flames, pilot lights, heat,
and other ignition sources.
• DO NOT light a cigarette or smoke.
WHEN OPERATING EQUIPMENT
• DO NOT tip engine or equipment at angle which causes
gasoline to spill.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT
• Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.
• Disconnect spark plug wire.
WHEN STORING GASOLINE OR EQUIPMENT WITH
FUEL IN TANK
• Store away from furnaces, stoves, water heaters, clothes
dryers or other appliances that have pilot light or other
ignition source because they can ignite gasoline vapors.
Gasoline and its vapors are extremely flammable
and explosive.
Fire or explosion can cause severe burns or
death.
WARNING
• DO NOT allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.
• Wear protective goggles, rubber apron, and rubber gloves.
Storage batteries give off explosive hydrogen gas
during recharging.
Hydrogen gas stays around battery for a long
time after battery has been charged.
Slightest spark will ignite hydrogen and cause
explosion.
You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is
extremely caustic.
Contact with battery fluid will cause severe
chemical burns.
DANGER
• DO NOT touch hot surfaces.
• Allow equipment to cool before touching.
Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).
Severe burns can occur on contact.
WARNING
• DO NOT tamper with governed speed. Generator supplies
correct rated frequency and voltage when running at governed
speed.
• DO NOT modify generator in any way.
Excessively high operating speeds increase risk of injury
and damage to generator.
Excessively low speeds impose a heavy load.
CAUTION
• See “Don’t Overload Your Generator” on page 10.
• 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 capacity can
damage generator and/or electrical devices connected
to it.
CAUTION
• Use generator only for intended uses.
• If you have questions about intended use, ask dealer or
contact Generac.
• 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.
Improper treatment of generator can damage it and
shorten its life.
CAUTION

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PowerBoss 5,500 Watt Storm-Plus Generator
120 Volt AC, 20 Amp, Duplex Receptacles — May be
used to supply electrical power for the operation of
120 Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting,
appliance, tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle — May
be used to supply electrical power for the operation of
120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical, lighting, appliance, tool and motor loads.
Air Cleaner — Uses a dry type filter element to limit the
amount of dirt and dust sucked into the engine.
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Push to reset circuit breakers
are provided to protect the generator against electrical
overload.
Fuel Tank — Capacity of five (5) U.S. gallons.
Grounding Wing Nut — Used for proper grounding of
unit (see page 7).
Oil Fill — Add engine oil here.
Recoil starter — Used to start the engine.
Rocker Switch — Set this switch to "On" before using
recoil starter. Set switch to "Off" to switch off engine.
Spark Arrester Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.
KNOWYOUR GENERATOR
Read this owner’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.
120 Volt AC, 20 Amp
Duplex Receptacles
Fuel Tank
Choke Lever
Recoil Starter
Rocker Switch
(on engine shroud)
Circuit
Breakers (AC)
120/240 Volt AC,
30 Amp
Receptacle
Spark Arrester Muffler
Air Cleaner
Grounding Wing Nut
Oil Fill

PowerBoss 5,500 Watt Storm-Plus Generator
5
ASSEMBLY
Your generator requires some assembly and is ready for
use after it has been properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the generator helpline at
1-800-270-1408.
IMPORTANT: Any attempt to run the unit before it has
been serviced with the recommended oil will result in an
engine failure.
Remove Generator From Carton
• Set the carton on a rigid flat surface with “This Side Up”
arrows pointing upward.
• Carefully open the top flaps of the shipping carton.
• Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.
• Remove all packing material, carton fillers, etc.
• Remove the generator from the shipping carton.
Install Wheel Kit
IMPORTANT:This wheel kit is not intended for
over-the-road use.
To install your wheel kit you need the following tools:
• Two 13mm box, open end, or socket wrenches
Install Wheel Kit as follows:
1. Place the bottom of the generator cradle on a flat,
even surface.Temporarily place unit on blocks to ease
assembly.
2. Slide axle through both axle mounting brackets on
cradle frame, as shown in Figure 1.
3. Slide a wheel over the axle.
NOTE: Be sure to install both wheels with the air
pressure valve on the outboard side.
4. Place the e-ring onto the groove in the axle.You may
add the flat washer if desired.
NOTE: Use retaining pins instead of e-clip, if applicable.
5. Place one end of the needle nose pliers on the bottom
of the axle and the other end of the pliers on top of
the e-ring. Seat the e-ring by pressing the pliers closed.
Support Leg
Hex Nut
Axle
Flat Washer
Cap Screw
Handle Assembly
Hex Nut
Wheel E-Ring
Figure 1 — Install Wheel Kit
Cap Screw

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PowerBoss 5,500 Watt Storm-Plus Generator
6. Repeat step 3 through 5 to secure second wheel.
7. Remove the temporary blocks.
8. To aid support leg assembly, rest generator on cradle,
engine end down.Attach the support leg with two
M8 x 16mm cap screws and two locking hex nuts as
shown.
9. Use two 13 mm wrenches to tighten leg hardware.
Rest generator on wheels and support leg.
10. Center the handle bracket on generator frame at
support leg end of cradle, as shown.
11. Attach handle bracket with two M8 x 45mm cap
screws and two locking hex nuts.
12. Check that all fasteners are tight and the tires are
inflated between 15-40 PSI.
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! Any attempt to crank or start the engine
before it has been properly filled with the recommended
oil may result in an engine failure.
To fill your engine with oil:
• Place generator on a level surface.
• Follow the oil grade recommendations and oil fill
instructions given in the engine owner’s manual.
NOTE: The generator’s revolving field rides on a
prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Gasoline
WARNING! NEVER fill fuel tank indoors. NEVER
fill fuel tank when engine is running or hot.Allow
unit to cool for two minutes before refueling. DO
NOT light a cigarette or smoke when filling the fuel
tank.
WARNING! DO NOT overfill the fuel tank.
Always allow room for fuel expansion.
• Use regular UNLEADED gasoline with the generator
engine. DO NOT use premium gasoline. DO NOT mix
oil with gasoline.
• Clean area around fuel fill cap, remove cap.
• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill.Allow about 1.5" of tank space for
fuel expansion (Figure 2).
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts, such as the
carburetor, fuel filter, fuel hose or tank during storage.Also,
experience indicates that alcohol–blended fuels (called
gasohol, ethanol or methanol) can attract moisture, which
leads to separation and formation of acids during storage.
Acidic gas can damage the fuel system of an engine while in
storage.
Be sure to review the precautions given in “Storage” on
page 12. NEVER use engine or carburetor cleaner products
in the fuel tank or permanent damage may occur.
Figure 2 — Typical Fuel Expansion Space
Fuel
Tank
1.5” Air Space

PowerBoss 5,500 Watt Storm-Plus Generator
7
GROUNDING THE
GENERATOR
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 3).
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth–driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices, especially when the unit is
equipped with a wheel kit. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
OPERATING THE
GENERATOR
CAUTION! NEVER start or stop the engine
with electrical loads connected to the receptacles
AND with the connected devices turned ON.
Starting the Engine
Disconnect all electrical loads from the generator. Use the
following start instruction steps by numerical order:
1. Turn the fuel valve to the “On” position (Figure 4).
2. Place the choke lever in the “Choke” position
(Figure 5).
Fuel Valve is shown
in the On position
Figure 4 — FuelValve
Figure 5 — Choke Lever
Figure 3 — Grounding Wing Nut
Grounding
Wing Nut

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PowerBoss 5,500 Watt Storm-Plus Generator
3. Set the rocker switch to “On” position (Figure 6).
4. Grasp the recoil handle and pull slowly until slight
resistance is felt.Then pull rapidly to start engine.
5. Move choke lever to “Run” position a short distance at
a time over several seconds in warm weather or
minutes in cold weather. Let engine run smoothly before
each change. Operate with choke in “Run” position.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase.This unit is equipped with a
low oil device which prevents the engine from being
started. See engine manual.
Refer to the engine owner’s manual for more
detailed starting instructions.
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hz electrical loads.
• DO NOT connect 240 Volt loads to the 120 Volt duplex
receptacles.
• DO NOT connect 3–phase loads to the generator.
• DO NOT connect 50 Hz loads to the generator.
•DO NOT OVERLOAD THE GENERATOR. See
“Don’t Overload the Generator” on page 10.
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles. NEVER start or stop engine with electrical
devices plugged in and turned ON.
• Let engine run at no-load for several minutes to stabilize
the internal temperatures of engine and generator.
• Move rocker switch to “Off” position.
• Move the fuel valve to the “Off” position.
RECEPTACLES
120/240 Volt AC, 30 Amp, Locking
Receptacle
Use a NEMA L14–30 plug with this receptacle. Connect a
4–wire cord set rated for 250 Volt AC loads at 30 Amps (or
greater) (Figure 7).You can use the same 4–wire cord if you
plan to run a 120 Volt load.
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 5,500 watts of power (5.5 kW)
at 30 Amps for 120Volts or 240 Volts.The outlet is
protected by a push–to–reset circuit breaker.
CAUTION! Although this outlet states it has a
120/240 Volt 22.9 Amp rating (up to 7,200 watts),
the generator is only rated for 5,500 watts.
Powering loads that exceed the wattage/amperage
capacity of the generator can damage it or cause
serious injuries.
Figure 7 — 120/240 Volt AC, 30 Amp Locking Receptacle
4-Wire Cord Set
240V
120V 120V W (Neutral)
X (Hot)
Y (Hot)
NEMA L14-30 Ground (Green)
Figure 6 — Rocker Switch

120 Volt AC, 20 Amp, Duplex
Receptacles
Each duplex receptacle (Figure 8) is protected against
overload by a push–to–reset circuit breaker.
Use each receptacle to operate 120Volt AC, single–phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125 Volt AC loads at 20 Amps (or greater).
CAUTION! These outlets are rated at 120 Volt
20 Amp each (up to 80 Amps).The generator is only
rated for up to 45.8 Amps. Powering loads that
exceed the wattage/amperage capacity of the
generator can damage it or cause serious injuries.
COLD WEATHER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.
Build a structure that will enclose three sides and the top
of the generator:
• Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from that
shown in Figure 9.
• Ensure a minimum of two feet clearance between open
side of box and nearest object.
• Face exposed end away from wind and elements.
• Enclosure should hold enough heat created by the
generator to prevent problems.
CAUTION!NEVER run unit indoors. DO NOT
enclose generator any more than shown. Remove
generator from shelter when temperature is above
40°F [4°C].
PowerBoss 5,500 Watt Storm-Plus Generator
9
Figure 8 — 120Volt, 20 Amp Duplex Receptacle
Figure 9 — Permanent Cold Weather Shelter
Wind

10
PowerBoss 5,500 Watt Storm-Plus Generator
DON'T OVERLOADYOUR
GENERATOR
Capacity
You must make sure your generator can supply enough
rated (running) and surge (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.
2. Total the rated (running) watts of these items.This is
the amount of power your generator must produce to
keep your items running. See Figure 10.
3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time, total
surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the
total rated watts from step 2.
Example:
Total Rated (Running) Watts = 3075
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875
Power Management
To prolong the life of your generator and attached devices,
it is important to take care when adding electrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it's engine.The correct
and safe way to manage generator power is to sequentially
add loads as follows:
1. With nothing connected to the generator, start the
engine as described in this manual.
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,
as described above.
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
Tool or Appliance Rated (Running)
Watts Additional Surge (Starting) Watts
Window Air
Conditioner 1200 1800
Refrigerator 800 1600
Deep Freezer 500 500
Television 500 -
Light (75 Watts) 75 -
3075 Total
Running Watts 1800 Highest Surge Watts
Tool or Appliance
Rated*
(Running)
Watts
Additional
Surge
(Starting)
Watts
Essentials
Light Bulb -75 watt
75
-
Deep Freezer
500
500
Sump Pump
800
1200
Refrigerator/Freezer -18 Cu. Ft.
800
1600
Water Well Pump -1/3 HP
1000
2000
Heating/Cooling
Window AC -10,000 BTU
1200
1800
Window Fan
300
600
Furnace Fan Blower -1/2 HP
800
1300
Kitchen
Microwave Oven -1000 Watt
1000
-
Coffee Maker
1500
-
Electric Stove -Single Element
1500
-
Hot Plate
2500
-
Family Room
DVD/CD Player
100
-
VCR
100
-
Stereo Receiver
450
-
Color Television -27”
500
-
Personal Computer w/17” monitor
800
-
Other
Security System
180
-
AM/FM Clock Radio
300
-
Garage Door Opener -1/2 HP
480
520
Electric Water Heater -40 Gallon
4000
-
DIY/Job Site
Quartz Halogen Work Light
1000
-
Airless Sprayer -1/3 HP
600
1200
Reciprocating Saw
960
960
Electric Drill -1/2 HP
1000
1000
Circular Saw -7 1/4”
1500
1500
Miter Saw -10”
1800
1800
Table Planer -6”
1800
1800
Table Saw/Radial Arm Saw -10”
2000
2000
Air Compressor -1-1/2 HP
2500
2500
Figure 10 - Wattage Reference Chart

PowerBoss 5,500 Watt Storm-Plus Generator
11
SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . . . .8,500 watts
Continuous Wattage Capacity . . . . . . . . . . .5,500 watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
Rated Maximum Continuous AC Load Current:
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . .45.8 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . .22.9 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . .60 Hertz
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . 5 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . 163 lbs.
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. NEVER operate a
damaged or defective generator.
Engine Maintenance
See engine owner’s manual for instructions.
If you need service for your engine, you need to determine
the engine identification number.To do so, remove the
rocker arm cover hood, item number 55 shown on
page 16, by removing the four nuts and washers holding it
in place.The engine model-type-trim number is stamped on
the side of the inner cover attached to the engine. Have
this number in hand when you call the engine service
center for assistance.
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.
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.
NOTE: DO NOT use a garden hose to clean generator.
Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air slots,
some of the water will be retained in voids and cracks of
the rotor and stator winding insulation.Water and dirt
buildup on the generator internal windings will eventually
decrease the insulation resistance of these windings.
To Clean the Generator
CAUTION! NEVER insert any object or tool
through the air cooling slots, even if the engine is
not running.
• Use a damp cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt and
debris.
• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.

12
PowerBoss 5,500 Watt Storm-Plus Generator
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 “To Clean the
Generator.”
• Check that cooling air slots and openings on generator
are open and unobstructed.
CAUTION! Storage covers can be flammable.
DO NOT place a storage cover over a hot
generator. Let the unit cool for a sufficient time
before placing the cover on the unit.
Engine Storage
See engine owner’s manual for instructions.
Other Storage Tips
• To prevent gum from forming in fuel system or on
essential carburetor parts, add fuel stabilizer into fuel
tank and fill with fresh gasoline. Run the unit for several
minutes to circulate the additive through the carburetor.
The unit and fuel can then be stored for up to
24 months. Fuel stabilizer can be purchased locally.
• DO NOT store gasoline from one season to another
unless it has been treated as described above.
• Replace fuel container if it starts to rust. Rust and/or dirt
in fuel can cause problems if it's used with this unit.
• Store unit in a clean and dry area.

PowerBoss 5,500 Watt Storm-Plus Generator
13
TROUBLESHOOTING
Problem
Cause
Solution
Engine is running, but
no AC output is
available.
1. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in good
condition.
4. Contact Generac service facility.
Engine runs good but
bogs down when
loads are connected.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator” on
page 10.
3. Contact Briggs service facility.
4. Contact Generac service facility.
Engine will not start;
or starts and runs
rough.
1. Rocker switch set to “Off”.
2. Low oil level.
3. Dirty air cleaner.
4. Out of gasoline.
5. Stale gasoline.
6. Spark plug wire not connected to
spark plug.
7. Bad spark plug.
8. Water in gasoline.
9. Overchoking.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
1. Set switch to “On”.
2. Fill crankcase to proper level.
3. Clean or replace air cleaner.
4. Fill fuel tank.
5. Drain gas tank and fill with fresh fuel.
6. Connect wire to spark plug.
7. Replace spark plug.
8. Drain gas tank; fill with fresh fuel.
9. Set choke to “Off” position.
10. Contact Briggs service facility.
11. Contact Briggs service facility.
12. Contact Briggs service facility.
Engine shuts down
during operation.
1. Out of gasoline.
2. Fault in engine.
1. Fill fuel tank.
2. Contact Briggs service facility.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. See “Don’t Overload the Generator” on
page 10.
2. Replace air filter.
3. Contact Briggs service facility.
Engine “hunts” or
falters.
1. Choke is opened too soon.
2. Carburetor is running too rich or too
lean.
1. Move choke to halfway position till engine
runs smoothly.
2. Contact Briggs service facility.

14
PowerBoss 5,500 Watt Storm-Plus Generator
SCHEMATIC

PowerBoss 5,500 Watt Storm-Plus Generator
15
WIRING DIAGRAM

16
PowerBoss 5,500 Watt Storm-Plus Generator
EXPLODED VIEW – MAIN UNIT

PowerBoss 5,500 Watt Storm-Plus Generator
17
PARTS LIST – MAIN UNIT
Item Part # Qty Description
1 B189444GS 1 CRADLE
2 70642GS 4 MOUNT,Vibration
3 76222GS 3 SCREW
4 190220GS 1 HOUSING, Engine Adapter
8 96796GS 1 WASHER
9 189186GS 1 DECAL, Cover,Air Cleaner
10 190274BGS 4 SCREW
11 187365FGS 1 SCREW
14 189009GS 1 BRACKET, Muffler
15 188551GS 1 GASKET, Exhaust
16 66476GS 2 SCREW, w/Lock Washer
17 189008GS 1 MUFFLER
18 60706GS 2 SCREW
19 83083GS 1 SCREEN, Spark Arrest
21 67989GS 11 NUT
22 20566GS 1 DECAL, 1-800 #
24 J189011GS 1 SHIELD, Heat
26 74908GS 4 SCREW
31 77816GS 1 DECAL, Hot Muffler
34 186347GS 1 COVER, Bearing Carrier
35 23762GS 1 WASHER
36 86494GS 1 SCREW,Wing
37 B2153GS 4 SCREW
39 188973GS 4 GROMMET,Tank
40 78831CGS 4 SCREW
41 80270GS 1 VALVE,Tank
42 78299GS 1 BUSHING, Plastic Tank
43 85134GS 1 CAP, Fuel Gauge
44 189022GS 1 ASSY,Tank, Fuel
(Includes Items 41 & 42)
Item Part # Qty Description
45 189235GS 1 DECAL, Start Instructions
46 22097GS 4 WASHER, Lock
47 22127GS 4 NUT
48 14353621GS 1 WIRE, Ground
49 26850GS 2 WASHER
50 B4986GS 1 DECAL, Ground, Green
51 92982GS 1 DECAL, Danger
52 189153GS 1 DECAL, Quick Ref.
54 BB3061GS 1 BOTTLE, Oil
55 187330GS 1 HOOD, Rocker Arm Cover
56 189025GS 1 DECAL, Panel, Side
57 188333GS 1 DECAL, Gas Fill
58 190355GS 1 ASSY, Control Panel (see page 19)
59 189164GS 4 NUT
60 275092 1 MANUAL, Engine
61 189439GS 1 MANUAL, Owners
62 73054GS 1 DECAL, Shut-Off, Fuel
63 43438GS 1 PLUG, 250V, 30A
66 45771GS 4 NUT
67 43107GS 4 SCREW
68 22129GS 6 WASHER, Lock
69 190442GS 1 ASSY,Alternator (see page 20)
70 189826GS 1 HOSE, Fuel, Formed
71 48031CGS 2 CLAMP, Hose, Band
72 70644GS 2 SCREW
73 86292GS 1 SCREW
900 NSP 1 ENGINE

18
PowerBoss 5,500 Watt Storm-Plus Generator
EXPLODED VIEW AND PARTS LIST – WHEEL KIT
Item Part # Qty Description
1 189715GS 1 ASSY, Handle
2 B1764GS 1 LEG, Mounting
3 52858GS 4 NUT, Lock
4 39287GS 2 SCREW
5 191267HGS 1 AXLE
6 B4966GS 2 WHEEL
7 191265GS 2 E-RING
8 22247GS 2 WASHER
9 42907GS 2 SCREW

PowerBoss 5,500 Watt Storm-Plus Generator
19
EXPLODED VIEW AND PARTS LIST – CONTROL PANEL
Item Part # Qty Description
1 188914GS 1 COVER, Lid, Control Panel
2 188889GS 1 CONTROL PANEL, Compact
3 189167GS 2 CLIP, Pin Retainer
4 189182GS 2 SPRING, Hinge
5 189166GS 2 PIN, Hinge
6 68759GS 2 OUTLET, 120 V, 20 A
7 189165GS 4 NUT, Push
8 84198GS 2 CAP, Circuit Breaker
9 75207GS 2 BREAKER, Circuit
10 43437GS 1 OUTLET, 120/240 V Locking, 30A
11 189164GS 2 NUT, Push
12 84543CGS 2 SCREW
13 93857GS 1 BAR, Retaining
14 188890GS 1 COVER, Back
15 82308GS 6 SCREW
16 22694GS 1 HSNG, Receptacle

20
PowerBoss 5,500 Watt Storm-Plus Generator
EXPLODED VIEW AND PARTS LIST – ALTERNATOR
Item Part # Qty Description
1 186059GS 1 ADAPTER, Mount
2 190032GS 1 ASSY, ROTOR
3 190079AGS 1 ASSY, STATOR
4 186060GS 1 RBC, with O-Ring (p/n 189197GS)
5 86308HGS 4 SCREW
6 91825GS 1 ASSY, Holder, Rectifier/Brush
7 66849GS 2 SCREW
8 22694GS 1 RECEPTACLE, 6 pin
9 81917GS 2 PIN, Roll
10 191051AGS 1 ASSY,WIRE
11 74908GS 1 SCREW
12 23762GS 1 WASHER, Shakeproof
13 190356GS 1 HARNESS,Wire