Generac Power Systems PowerBOSS Storm-Plus 1642-0 User manual

Portable Generator Owner's Manual
A his is the safety alert symbol. It isusedto alert you to potential personal injury hazards.Obey all safety messagesthat follow this symbol to avoid possible injury or death.
Questions? Help is just a moment away!
Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT; Sat.8-4 CT
Web: www.generac-portables.com or www.briggsandstratton.com
Model No. 1642-0 (5,500Watt AC Generator) Manual No. 189027 Revision 2 (06/01/2001)

EQUIPMENT
DESCRIPTION
This generator isan engine-driven, revolving field,alternating
current (AC) generator. It was designedto supply electrical
power for operating compatible electrical lighting, appliance,
tool and motor loads.
This manualcontains informationfor a generator that
operates 120and/or 240Volt AC, singlephase,60Hz devices
that require up to 5,500watts (5.5 kW) of power that pull
up to 45.8 Amps at 120Vottsor 22.9Amps at 240Volts.
CAUTION! Do Not exceed the generator's
wattage/amperage capacity.Add up the rated watts of all
devicesyou will connect to generator receptacles at one
time.This total should not be greater than 5,500 watts for
this generator. Review"Don't Overload the Generator" on
page 9.
The generator's revolving field isdriven at about 3,600 rpm
by a single-cylinder engine.
Every effort hasbeen madeto ensure that informationin
this manualisaccurate and current However, Generac
reservesthe right to change,alter or otherwise improvethe
product and this document at anytime without prior
notice.
_AUTION! Do Not tamper with engine
governed speed.High operating speeds are
dangerousand increaserisk of personal injuryor
damageto equipment.The generator supplies
correct rated frequency and voltage only when
running at proper governed speed.Incorrect
frequency and/or voltage can damagesome
connected electrical loads.Operating at excessively
low speedsimposesa heavy load.When adequate
engine power isnot availableengine life may be
shortened.
The Emission Control System for this generator is
warranted for standards set by the Environmental
Protection Agency.For warranty informationrefer to the
engine owner's manual.
SAFETY RULES
Thisgenerator set was designed and manufactured for
specific applications. Do Not attempt to modify the unitor
use it for anyapplication it was not designedfor. If you have
anyquestions about your generator's application, askyour
dealer or consult the factory.
The manufacturer could not possibly anticipate every
circumstance that might involvea hazard.For that reason
warnings in the manualand warnings on tags or decals
affixed to the unit are not all-inclusive. If you intendto
handle,operate or service the unit by a procedure or
method not specifically recommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafeor pose a threat to you and
others.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
_, ARNING! You must isolatethe generator
from the electric utility usingapproved transfer
equipment ifthis unit isused for backup power.
Failure to isolate the generator from the
power utility may result in injury or death to
electric utility workers and damage to the
generator due to a backfeed of electrical energy.
Whenever the unit isproviding backup power, the
electric utility must be notified.
_|k DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. If breathed in
sufficient concentrations, carbon monoxide
can cause unconsciousness or death. Operate
this equipment outdoors where adequate ventilation
isavailable.
/2

•The generator produces avery powerful voltage that can
cause serious injury or death by electrocution. Never
touch bare wires or receptacles.Never permit a child or
any unqualified person to operate the generator.
• Never handleany kind of electrical cord or devicewhile
standing in water, while barefoot or while hands or feet
are wet Death or serious injury from electrocution may
result.
• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
work).
• Never useworn, bare,frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damagefrom electrical shock may result
•Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Never allow smoking, open flames,
sparks or heat in the vicinity while handling
gasoline. Avoid spielinggasolineon a hot engine.Comply
with all laws regulating storage and handlingof gasoline.
•Do Not overfill the fuel tank.Always allow room for fuel
expansion.If tank is overfllled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
•Never store a generator with fuel in the tank where
gasolinevapors might reach an open flame,spark or pilot
light (ason a furnace, water heater,clothes dryer). FIRE
or an EXPLOSION may result.
• The unit requires an adequateflow of cooling air for its
continued proper operation. Never operate the unit
inside anyroom or enclosure where the free flow of
cooling air intoand out of the unit might be obstructed.
Allow at least2 feet of clearanceon all sidesof generator,
evenwhile operating unit outdoors, or you could damage
the unit
• Never start, or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting any electrical loads. Disconnect all electrical
loads before shutting down the generator.
•Do Not insert anyobject through cooling slots of the
engine.Youcould damagethe unit or injure yourself.
•Never operate the generator:
in rain; in any enclosed compartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is observed
while unit is running; if unit vibrates excessively.
GROUNDING THE
G EN ERATO R
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 I).
Generally,connecting a No. 12AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth-driven copper or brassgrounding rod
(electrode) provides adequateprotection againstelectrical
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.Proper grounding also helps
dissipatestatic electricity, which often builds up in
ungrounded devices.
/3

Yourgeneratorrequiressomeassemblyandisready for
use after it hasbeen 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 G EN ERATOR
FROM CARTON
•Set the carton on a rigid flat surfacewith "This Side Up"
arrows pointing upward.
• Carefully open the top flapsof the shippingcarton.
• Cut down corners at one end of carton from top to
bottom and laythat side of carton down flat
• Removeall packing material, carton fillers, etc.
• Removethe generator from the shipping carton.
CARTON CONTENTS
Check all contents. If anyparts are missingor damaged,call
the generator helpline at 1-800-270-1408.
• The generator
• Generator and engine owner's manuals
• Locking 30Amp plug
• Engineoil
• Wheel kit
INSTALL WHEEL KIT
IMPORTANT:This wheel kit is not intended for
over-the-road use.
To installyour wheel kit you need the followingtools:
• Two 13mm box, openend,or socket wrenches
Install Wheel Kit as follows:
I. Placethe bottom of the generator cradle on a flat,
even surface.Temporarily place uniton blocks to ease
assembly.
2. Slide axle through both axle mounting brackets on
cradle frame, as shown in Figure 2.
Cap Screw
\\
Handle Assembly
\\
Hex FlatWasher
Mounting Leg J
Use Existing Fasteners
Axle
/
Wheel
O_
/
F
/
Retaining Pin
/4

3. Slideawheel over the axle.
NOTE: Be sure to installboth wheelswith the air
pressure valve on the outboard side.
4. Retain wheel on axle with the retaining pin.You may
acidthe fiat washer if desired.
5. Repeat step 3 and 4 to secure second wheel.
6. Removethe existing hardware from the vibration
mounts with 13mm wrench. Use the same hardware to
attach the mounting leg.
7. Removethe temporary blocks.
8. Center the handle bracket on generator frame at
control panel end of cradle.
9. Attach handle bracket with two cap screws and two
hex nuts. Use two 13mm wrenches to tighten
hardware.
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
_hL WARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine is running or hot. 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 gasolinewith the generator
engine.Do Not use premium gasoline. Do Not mix oil
with gasoline.
• Clean areaaround fuel fill cap,remove cap.
• Add unleaded regular gasoline,slowly to fuel tank. Be
careful not to overfill.Allow about I/2" of tank spacefor
fuel expansion (Figure 3).
1/2" Air Space Tank
• 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 asthe
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.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See "Storage"
on page I I. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
/5

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. FuelTank
Circuit
Breakers (AC)
SparkArrester Muffler
Choke Lever
Air Cleaner
120/240Volt AC,
30 Amp
Receptacle
Recoil Starter
Grounding Wing Nut
Rocker Switch
(on engine shroud) 120Volt AC, 20 Amp Duplex Receptacles
120Volt AC, 20 Amp, Duplex Receptacles -- May be
usedto supply electrical power for the operation of
120Volt AC, 20 Amp, singlephase,60 Hz electrical lighting,
appliance,toot and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle -- May
be usedto supply electrical power for the operation of
120and/or 240Volt AC, 30Amp, singlephase,60 Hz
electrical lighting,appliance,tool and motor loads.
Air Cleaner -- Uses a dry type filter element and foam
pre-cteaner to limitthe amount of dirt and dust sucked
into the engine.
Choke Lever -- Used when starting a cold engine.
Circuit Breakers (AC) -- Pushto reset circuit breakers
are provided to protect the generator againstelectrical
overload.
Fuel Tank -- Capacity of five (5) U.S.gallons.
GroundingWing Nut -- Used for proper grounding of
unit (seepage 3).
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 isequipped with a spark arrester screen.
/6

OPERATING THE
GEN ERATO R
,_ CAUTION! Never start or stop the engine with
electrical loadsconnectedto the receptaclesAND
with the connected devices turned ON.
Starting the Engine
Disconnect all electrical loadsfrom the generator. Use the
following start instructionsteps by numerical order:
I. Turn the fuel valve to the "On" position (Figure 4).
FuelValveisshown
in the On position
2. Placethe choke leverin the "Choke" position
(Figure5).
mu
4. Grasp the recoil handle and pull slowly untilslight
resistance isfelt.Then pull rapidly to start engine.
5. Move choke leverto "Run" position a short distanceat
a time over severalsecondsin warm weather or
minutes in cold weather.Let engine run smoothly before
eachchange.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 isequipped with a
Low Oil Shutdown System.Seeengine manual.
Refer to the engine owner's manual for complete
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 VottAC,
singlephase,60 Hz electrical loads.
•Do Not connect 240Volt loadsto the 120Volt duplex
receptacles.
•Do Not connect 3_hase loadsto the generator.
•Do Not connect 50 Hz loads to the generator.
•DO NOT OVERLOADTHE GENERATOR. See
"Don't Overload the Generator" on page9.
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles.Never start or stop engine with electrical
devicesplugged in and turned ON.
• Let engine run at no-load for several minutes to stabilize
the internal temperatures of engine andgenerator.
• Move rocker switch to "Off" position.
• Move the fuel valveto the "Off" position.
3. Set the rocker switch to "On" position (Figure 6).
in On
I7

RECEPTACLES
120/240 Volt AC, 30 Amp, Locking
Receptacle
Use a NEMA LI4-30 plug with this receptacle.Connect a
4-wire cord set rated for 250Volt AC loads at 30 Amps (or
greater) (Figure 7).You can usethe same 4-wire cord if you
_lanto run a 120Volt load.
120 Volt AC, 20 Amp, Duplex
Receptacles
Eachreceptacle (Figure8) isprotected against overload by
a 20 Amp push-to-reset circuit breaker.
4-Wire CordSet
Y (Hot) X (H_)
Ground
NEMA L14=30 (Green)
This receptacle powers 120/240Volt AC, 60 Hz,single
phaseloads requiring up to 3,600 watts of power at
30 Amps for 120Volts;5,500 watts of power (5.5 kW) at
30 Amps for 240Volts.The outlet isprotected bya 20 Amp
push-to-reset circuit breaken
_, AUTION! Although this outlet states it has a
120/240 Volt 30 Amp rating (up to 7,200 watts), the
generator isonly rated for 5,500 watts. Powering
loads that exceed the wattage/amperage capacity of
the generator can damage it or cause serious injuries.
Use each receptacle to operate 120Volt AC, single-phase,
60 Hz electrical loadsrequiring up to 2,400 watts (2.4 kW)
at 20Amps of current. Use cord sets that are rated for
125Volt AC loadsat 20Amps (or greater).
/8

DON'T OVERLOAD TH E
G EN ERATO R
Overloading a generator in excess of its rated wattage
capacity can result in damageto the generator and/or
connected electrical devices.Observe the following, to
prevent overloading the unit:
•Add up the total wattage of all electrical devicesto be
connected at one time.This total should NOT be greater
than the generator's wattage capacity.
• If the appliance,tool or motor does not give wattage,
multiply 120Volts times ampere rating to determine
watts (volts x amps = watts).
The rated wattageof lights can be taken from wattage
listed on the lightbulbs.The rated wattageof tools,
appliancesand motors can usually be found on a data
plate or decal affixed to the device.Use Figure 9 below
asa general reference.
Someelectric motors, such asinductiontypes, require
about three times more watts of power for starting than
for running.This surge of power lastsfor only a few
secondswhen starting such motors. Be sure you allow
for this high starting wattage when selectingelectrical
devicesto connect to your generator. First figure the
watts needed to start the largest motor.Add to that
figure the running watts of all other connected loads.
Recreational/Home Uses
Tool/Appliance .................................................... Watts
AM/FM clock radio ....................................................................50
Light bulb....................................................................................100
Fan................................................................................................200
20" color TV ..............................................................................400
*Deep freezer ...........................................................................500
Personal computer and 15" monitor ...................................800
*1/3 hp furnace fan blower ....................................................800
Microwave oven ........................................................................800
*18 cu ft refrigerator ...............................................................800
Sump pump ..............................................................................1000
Electric skillet ..........................................................................1250
*Y2 hp water well pump .......................................................1400
*12,000 Btu window air conditioner ................................1400
Space heater ............................................................................1800
Electric water heater ............................................................4000
Professional/Contractor Uses
Tool/Appliance .................................................... Watts
"1/3 hp airless sprayer ............................................................600
3/8" hammer drill .....................................................................600
Variable speed Sawzall® .........................................................960
Y2" power drill ........................................................................1000
Quartz-halogen work light ..................................................1000
Belt sander ...............................................................................1200
7¼" circular saw ...................................................................1500
7¼" worm drive saw ...........................................................1600
*1/2 hp air compressor ........................................................1800
*I0" power miter saw ...........................................................1800
6" bench grinder .....................................................................1800
*6" table planer.......................................................................1800
*I0" table/radial arm saw .....................................................2000
Wire feed welder ...................................................................2400
* allow 3 times listed watts for starting this device
I9

SPECIFICATIONS
Maximum SurgeWatts ................. 8,500 watts
Continuous Wattage Capacity ........... 5,500 watts
Power Factor .............................. 1.0
Rated Maximum Continuous AC Load Current:
At 120Volts ....................... 45.8Amps
At 240 Volts ....................... 22.9Amps
Phase................................. I-phase
Rated Frequency ....................... 60 Hertz
FuelTank Capacity................... 5 U.S.gallons
ShippingWeight ......................... 148 Ibs.
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on atimely
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.
_, AUTION! Avoid prolonged or repeated skincontact with usedmotor oil. Used motor oil has
been shown to cause skin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soap and water.
KEEPOUT OF REACH OF CHILDREN. DON'T
POLLUTE.CONSERVERESOURCES.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 wilt 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
_, AUTION! Never insertanyobject or tool
through the air cooling slots, even ifthe 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) maybe used to
blow awaydirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.
/10