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Model / Modelo030249 & 030255(5500W)Operator’s ManualManual del OperarioQuestions? Help is just a moment away!Preguntas? La ayuda es justa un momento lejos!Call: Generator Helpline / Llamada: Generador Helpline1-800-743-4115 M-F 8-5 CTWARNINGBefore using this product, read this manual and follow allSafety Rules and Operating Instructions.ADVERTENCIAAntes de utilizar el producto, lea este manual y siga todas lasReglas de Seguridad e Instrucciones de Uso.PowerBOSS is a trademark of Briggs & Stratton Power Products.PowerBOSS es una marca registrada de Briggs & Stratton Power Products.Manual No. 198061GS Rev. C (06/27/2006)BRIGGS & STRATTON POWER PRODUCTS GROUP, LLCJEFFERSON,WISCONSIN, U.S.A.
PowerBOSS SAFETY RULES5500W Portable GeneratorSAVE THESE INSTRUCTIONSTABLE OF CONTENTSSAFETY RULESSafety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15This is the safety alert symbol. It is used toalert you to potential personal injury hazards.Obey all safety messages that follow thissymbol to avoid possible injury or death.The safety alert symbol ( ) is used with a signal word(DANGER, CAUTION,WARNING), a pictorial and/or asafety message to alert you to hazards. DANGER indicatesa hazard which, if not avoided, will result in death or seriousinjury. WARNING indicates a hazard which, if not avoided,could result in death or serious injury. CAUTIONindicates a hazard which, if not avoided, might result inminor or moderate injury. CAUTION, when usedwithout the alert symbol, indicates a situation that couldresult in equipment damage. Follow safety messages toavoid or reduce the risk of injury or death.EQUIPMENTDESCRIPTIONRead this manual carefully and becomefamiliar with your generator. Know itsapplications, its limitations and any hazardsinvolved.WARNINGThe generators described herein are an engine-driven,revolving field, alternating current (AC) device. Each isdesigned to supply electrical power for operatingcompatible electrical lighting, appliance, tool, and motorloads. Each unit's revolving field rotates at about 3,600 rpm.The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.Hazard Symbols and MeaningsCAUTION! DO NOT exceed the generator’swattage/amperage capacity. See “Don’t OverloadGenerator”.Every effort has been made to ensure that information inthis manual is accurate and current. However, we reservethe right to change, alter or otherwise improve the productand this document at any time without prior notice.Operator’s ManualThe Emission Control System for this generator iswarranted for standards set by the EnvironmentalProtection Agency and the California Air Resources Board.For warranty information refer to the Engine Operator’sManual.Copyright 2006 Briggs & Stratton Power ProductsGroup, LLC. All rights reserved. No part of this materialmay be reproduced or transmitted in any form by anymeans without the express written permission of Briggs &Stratton Power Products Group, LLC.2Electrical ShockExplosionFireToxic FumesKickbackFlying ObjectsHot Surface
SAFETY RULESPowerBOSS 5500W Portable GeneratorWARNINGFuel and its vapors are extremely flammable andexplosive.Fire or explosion can cause severe burns ordeath.Using a generator indoors WILL KILL YOUIN MINUTES.Exhaust contains carbon monoxide, apoison gas you cannot see or smell.WHEN ADDING OR DRAINING FUEL Turn generator OFF and let it cool at least 2 minutes beforeremoving fuel cap. Loosen cap slowly to relieve pressure intank. 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, andother ignition sources. 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 tip engine or equipment at angle which causes fuel tospill. This generator is not for use in mobile equipment or marineapplications.WHEN TRANSPORTING OR REPAIRINGEQUIPMENT Transport/repair with fuel tank EMPTY or with fuel shutoffvalve OFF. Disconnect spark plug wire.WHEN STORING FUEL OR EQUIPMENT WITH FUELIN TANK Store away from furnaces, stoves, water heaters, clothesdryers or other appliances that have pilot light or otherignition source because they can ignite fuel vapors.NEVER use in the home ONLY use outdoors andor in partly enclosedfar from open windows,areas such as garages. doors, and vents.WARNINGRunning generator gives off carbon monoxide,an odorless, colorless, poison gas.Breathing carbon monoxide can cause nausea,fainting or death. Operate generator ONLY outdoors. Keep exhaust gas from entering a confined area throughwindows, doors, ventilation intakes or other openings. DO NOT operate generator inside any building or enclosure(even if doors or windows are open), including the generatorcompartment of a recreational vehicle (RV).WARNINGGenerator produces powerful voltage.Failure to isolate generator from power utilitycan result in death or injury to electric utilityworkers due to backfeed of electrical energy. When using generator for backup power, notify utilitycompany. Use approved transfer equipment to isolategenerator from electric utility. Use a ground fault circuit interrupter (GFCI) in any damp orhighly 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 standingin water, while barefoot, or while hands or feet are wet. DO NOT allow unqualified persons or children to operate orservice generator.WARNING This generator does not meet U. S. Coast Guard Regulation33CFR-183 and should not be used on marine applications. Failure to use the appropriate U. S. Coast Guard approvedgenerator could result in death or serious injury and/orproperty damage.3
PowerBOSS 5500W Portable GeneratorSAFETY RULESCAUTIONWARNINGExcessively high operating speeds increase risk of injuryand damage to generator.Excessively low speeds impose a heavy load.Rapid retraction of starter cord (kickback) willpull hand and arm toward engine faster thanyou can let go.Broken bones, fractures, bruises or sprains couldresult. DO NOT tamper with governed speed. Generator suppliescorrect rated frequency and voltage when running at governedspeed. DO NOT modify generator in any way. When starting engine, pull cord slowly until resistance is feltand then pull rapidly to avoid kickback. NEVER start or stop engine with electrical devices plugged inand turned on.CAUTIONWARNINGExceeding generators wattage/amperage capacity candamage generator and/or electrical devices connectedto it.Running engines produce heat.Temperature ofmuffler and nearby areas can reach or exceed150 F (65 C).Severe burns can occur on contact.Exhaust heat/gases can ignite combustibles,structures or damage fuel tank causing a fire. See “Don’t Overload Generator”. Start generator and let engine stabilize before connectingelectrical loads. Connect electrical loads in OFF position, then turn ON foroperation. Turn electrical loads OFF and disconnect from generatorbefore stopping generator. DO NOT touch hot surfaces and avoid hot exhaust gases. Allow equipment to cool before touching. Keep at least 5 ft. (152 cm) clearance on all sides of generatorincluding overhead. Code of Federal Regulation (CFR) Title 36 Parks, Forests, andPublic Property require equipment powered by an internalcombustion engine to have a spark arrester, maintained ineffective working order, complying to USDA Forest servicestandard 5100-1C or later revision. In the State of California aspark arrester is required under section 4442 of the CaliforniaPublic resources code. Other states may have similar laws.CAUTIONImproper treatment of generator can damage it andshorten its life. Use generator only for intended uses. If you have questions about intended use, ask dealer or call1-800-743-4115. 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 disconnectthem from generator. Shut off generator if:-electrical output is lost;-equipment sparks, smokes, or emits flames;-unit vibrates excessively.WARNINGUnintentional sparking can result in fire orelectric shock.WHEN ADJUSTING OR MAKING REPAIRS TO YOURGENERATOR Disconnect the spark plug wire from the spark plug and placethe 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.4
FEATURESPowerBOSS 5500W Portable GeneratorKNOW YOUR GENERATORRead 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 andadjustments. Save this manual for future reference.Alternator may varyslightly in appearancefrom that shown hereFuel TankRocker SwitchChoke LeverRecoil StarterGroundingFastenerOil FillCircuitBreakers (AC)120/240 Volt AC,30 Amp ReceptacleSpark ArresterMufflerAir Cleaner120 Volt AC, 20 AmpDuplex Receptacle120 Volt AC, 20 Amp, Duplex Receptacle — May beused to supply electrical power for the operation of120 Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting,appliance, tool and motor loads.120/240 Volt AC, 30 Amp Locking Receptacle — Maybe used to supply electrical power for the operation of120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hzelectrical, lighting, appliance, tool and motor loads.Air Cleaner — Protects engine by filtering dust anddebris out of intake air.Choke Lever — Used when starting a cold engine.Circuit Breakers (AC) — Push-to-reset circuit breakersare provided to protect the generator against electricaloverload.Fuel Tank — Capacity of seven (7) U.S. gallons (26.5l).Grounding Fastener — Consult your local agency havingjurisdiction for grounding requirements in your area.Oil Fill — Add engine oil here.Recoil Starter — Used to start the engine.Rocker Switch — Set this switch to "On" before usingrecoil starter. Set switch to "Off" to switch off engine.Spark Arrester Muffler — Exhaust muffler lowersengine noise and is equipped with a spark arrester screen.5
PowerBOSS ASSEMBLY5500W Portable GeneratorASSEMBLY 30 Amp extension cord Wheel kitYour generator requires some assembly and is ready foruse after it has been properly serviced with therecommended oil and fuel.Install Wheel KitNOTE: Wheel kit is not intended for over-the-road use.You will need the following tools to install thesecomponents: 2 - 13mm wrenches Socket wrench with a 13mm socket Pliers Safety glassesIf you have any problems with the assembly of yourgenerator, please call the generator helpline at1-800-743-4115. If calling for assistance, please have themodel, revision, and serial number from the data tag available.Unpacking the Generator1.2.3.4.Set the carton on a rigid flat surface.Remove everything from carton except generator.Open carton completely by cutting each corner fromtop to bottom.Leave generator on carton to install wheel kit.Refer to Figure 1 and install the wheel kit as follows:1. Tip generator so that engine end is up.2.Slide axle through both mounting brackets.3.Place a wheel on each side with air valve facing out.4.Place a washer on axle and then place an e-ring in axlegroove.5.Install e-ring with pliers, squeezing from top of e-ringto bottom of axle.Carton ContentsCheck all contents. If any parts are missing or damaged, callthe generator helpline at 1–800–743–4115. The generator Generator operator’s manual Engine operator’s manual Engine oil Three packets of fuel stabilizerCAUTIONE-rings can cause eye injury.E-rings can spring back and become airbornewhen installing or removing. Always wear eye protection when installing/removing e-rings.Figure 1 — Install Wheel KitCapscrewNutHandleWasherAxleCapscrewSupport LegNutWheel6E-Ring
ASSEMBLYPowerBOSS 5500W Portable Generator6.Repeat step 4 and 5 to secure second wheel.Add Fuel7.Tip generator so that engine side is down.8.Line up holes in support leg with holes in generatorframe.NOTE: This gasoline engine is certified to operate ongasoline. Exhaust Emission Control System: EM (EngineModifications).9.Attach support leg using 2 capscrews (M8 x 16 mm)and 2 hex nuts.Tighten with a 13mm socket wrenchand 13mm wrench.WARNINGFuel and its vapors are extremely flammable andexplosive.Fire or explosion can cause severe burns ordeath.10. On support leg end of generator, slide handle ontocenter of top of frame.11. Attach handle using two long (M8 x 45mm) cap screwsand two locking (M8) hex nuts.Tighten with a 13mmsocket and wrench.WHEN ADDING FUEL Turn generator OFF and let it cool at least 2 minutes beforeremoving fuel cap. Loosen cap slowly to relieve pressure intank. Fill fuel tank outdoors. DO NOT overfill tank. Allow space for fuel expansion. Wait for spilled fuel to evaporate before starting engine. Keep fuel away from sparks, open flames, pilot lights, heat, andother ignition sources. DO NOT light a cigarette or smoke.12. Return generator to normal operating position (restingon wheels and support leg).BEFORE STARTING THEENGINEAdd Engine Oil1.Use clean, fresh, regular UNLEADED gasoline with aminimum of 87 octane. DO NOT use fuel whichcontains Methanol. DO NOT mix oil with fuel.2.Clean area around fuel fill cap, remove cap.3.Slowly add regular unleaded fuel to fuel tank. Be carefulnot to overfill. Allow about 1.5" (4cm) of tank spacefor fuel expansion (Figure 2). Place generator on a level surface.CAUTIONAny attempt to crank or start the engine before it hasbeen properly filled with the recommended oil willresult in equipment failure. Refer to engine manual for oil fill information. Damage to equipment resulting from failure to follow thisinstruction will void warranty.1.5” Air SpaceFigure 2 - Fuel Expansion Refer to engine operator’s manual and follow oilrecommendations and instructions.NOTE: Check oil often during engine break–in. Refer toengine operator’s manual for recommendations.NOTE: The alternator assembly rotates on a prelubricatedand sealed ball bearing that requires no additionallubrication for the life of the bearing.4.7TankFuelInstall fuel cap and let any spilled fuel evaporate beforestarting engine.
PowerBOSS OPERATION5500W Portable GeneratorUSING THE GENERATORGenerator LocationGenerator ClearanceSystem GroundWARNINGThe generator has a system ground that connects thegenerator frame components to the ground terminals onthe AC output receptacles.The system ground is connectedto the AC neutral wire (see “Equipment Description”,earlier in this manual).Exhaust heat/gases can ignite combustibles,structures or damage fuel tank causing a fire. Keep at least 5 ft. (152 cm) clearance on all sides of generatorincluding overhead.Place generator in a well ventilated area, which will allowfor removal of deadly exhaust gas. DO NOT placegenerator where exhaust gas could accumulate and enterinside or be drawn into a potentially occupied building.Ensure exhaust gas is kept away from any windows, doors,ventilation intakes or other openings that can allow exhaustgas to collect in a confined area (Figure 3). Prevailing windsand air currents should be taken into consideration whenpositioning generator.Special RequirementsThere may be Federal or State Occupational Safety andHealth Administration (OSHA) regulations, local codes, orordinances that apply to the intended use of the generator.Please consult a qualified electrician, electrical inspector, orthe local agency having jurisdiction. In some areas, generators are required to be registeredwith local utility companies. If the generator is used at a construction site, there maybe additional regulations which must be observed.Using a generator indoors WILL KILL YOUIN MINUTES.Connecting to a Building’s ElectricalSystemExhaust contains carbon monoxide, apoison gas you cannot see or smell.Connections for standby power to a building’s electricalsystem must be made by a qualified electrician.Theconnection must isolate the generator power from utilitypower, and must comply with all applicable laws andelectrical codes.WARNINGNEVER use in the home ONLY use outdoors andor in partly enclosedfar from open windows,areas such as garages. doors, and vents.Generator produces powerful voltage.Failure to isolate generator from power utilitycan result in death or injury to electric utilityworkers due to backfeed of electrical energy.Figure 3 — Generator Clearance When using generator for backup power, notify utilitycompany. Use approved transfer equipment to isolategenerator from electric utility. Use a ground fault circuit interrupter (GFCI) in any damp orhighly 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 standingin water, while barefoot, or while hands or feet are wet. DO NOT allow unqualified persons or children to operate orservice generator.Typical Generator ShownExhaust Port8
OPERATIONPowerBOSS 5500W Portable GeneratorOPERATING THEGENERATORWARNINGRunning engines produce heat.Temperature ofmuffler and nearby areas can reach or exceed150 F (65 C).Severe burns can occur on contact.Exhaust heat/gases can ignite combustibles,structures or damage fuel tank causing a fire.Starting the EngineDisconnect all electrical loads from the generator. Use thefollowing start instructions:1. Make sure unit is on a level surface.IMPORTANT: Failure to start and operate unit on a levelsurface will cause the unit not to start or to shut downduring operation.2. Turn the fuel valve to the “On” position (Figure 4).Thefuel valve handle should be vertical (pointing towardthe ground) for fuel to flow. DO NOT touch hot surfaces and avoid hot exhaust gases. Allow equipment to cool before touching. Keep at least 5 ft. (152 cm) clearance on all sides of generatorincluding overhead. Code of Federal Regulation (CFR) Title 36 Parks, Forests, andPublic Property require equipment powered by an internalcombustion engine to have a spark arrester, maintained ineffective working order, complying to USDA Forest servicestandard 5100-1C or later revision. In the State of California aspark arrester is required under section 4442 of the CaliforniaPublic resources code. Other states may have similar laws.Figure 4 — Fuel ValveConnecting Electrical Loads Let engine stabilize and warm up for a few minutes afterstarting. 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 duplexreceptacles. 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
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— Protec
