Generac Power Systems Portable Generator Manuel utilisateur

Owner’s Manual

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that 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

Web: www.generac-portables.com or www.briggsandstratton.com

Model No. 1658-0 (5,000 Watt AC Generator) Manual No. 189633GS Revision 1 (08/23/2001)

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page

Table of Contents

• Generator

• Engine oil

• Owner's manual

• Engine manual

*If any parts are missing or damaged, call 1-800-270-1408.

Parts Included*

5,000 Watt Portable Generator

EQUIPMENT

DESCRIPTION

This generator is an engine-driven, revolving field, alternating

current (AC) generator. It was designed to supply electrical

power for operating compatible electrical lighting, appliance,

tool and motor loads.

This manual contains information for a generator that

operates 120 and/or 240Volt AC, single phase, 60Hz devices

that require up to 5,000 watts (5.0 kW) of power that pull

up to 41.7 Amps at 120Volts or 20.8 Amps at 240Volts.

CAUTION! Do Not exceed the generator’s

wattage/amperage capacity.Add up the rated watts of all

devices you will connect to generator receptacles at one

time.This total should not be greater than 5,000 watts for

this generator. Review “Don’t Overload the Generator” on

page 8.

The generator’s revolving field is driven at about 3,600 rpm

by a single-cylinder engine.

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.

CAUTION! Do Not tamper with engine

governed speed. High operating speeds are

dangerous and increase risk of personal injury or

damage to equipment.The generator supplies

correct rated frequency and voltage only when

running at proper governed speed. Incorrect

frequency and/or voltage can damage some

connected electrical loads. Operating at excessively

low speeds imposes a heavy load.When adequate

engine power is not available engine life may be

shortened.

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

This generator set was designed and manufactured for

specific applications. Do Not attempt to modify the unit or

use it for any application it was not designed for. If you have

any questions about your generator’s application, ask your

dealer or consult the factory.

The manufacturer could not possibly anticipate every

circumstance that might involve a hazard. For that reason

warnings in the manual and warnings on tags or decals

affixed to the unit are not all–inclusive. If you intend to

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 unsafe or 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.

WARNING! You must isolate the generator

from the electric utility using approved transfer

equipment if this unit is used 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 unit is providing backup power, the

electric utility must be notified.

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

is available.

The engine exhaust from this product contains

chemicals known to the State of California

to cause cancer, birth defects,

or other reproductive harm.

WARNING:

5,000 Watt Portable Generator

• The generator produces a very 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 handle any kind of electrical cord or device while

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 use worn, bare, frayed or otherwise damaged

electrical cords with the generator. Death, serious injury

and property damage from 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 spilling gasoline on a hot engine. Comply

with all laws regulating storage and handling of gasoline.

•Do Not overfill the fuel tank.Always allow room for fuel

expansion. If tank is overfilled, fuel can overflow

onto a hot engine and cause a FIRE or an

EXPLOSION.

•Never store a generator with fuel in the tank where

gasoline vapors might reach an open flame, spark or pilot

light (as on a furnace, water heater, clothes dryer). FIRE

or an EXPLOSION may result.

• The unit requires an adequate flow of cooling air for its

continued proper operation. Never operate the unit

inside any room or enclosure where the free flow of

cooling air into and out of the unit might be obstructed.

Allow at least 2 feet of clearance on all sides of generator,

even while 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 any object through cooling slots of the

engine.You could damage the 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

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 1).

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. Proper grounding also helps

dissipate static electricity, which often builds up in

ungrounded devices.

Figure 1 — Grounding Wing Nut

Grounding Wing Nut

5,000 Watt Portable Generator

Your generator is ready for use after it has been properly

serviced with the recommended oil and fuel.

If you have any problems with the 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.

CARTON CONTENTS

Check all contents. If any parts are missing or damaged, call

the generator helpline at 1-800-270-1408.

• The generator

• Generator and engine owner’s manuals

• Engine oil

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 fuel 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 9. 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

5,000 Watt Portable Generator

120 Volt AC, 20 Amp, Duplex Receptacle — 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, 20 Amp Locking Receptacle — May

be used to supply electrical power for the operation of

120 and/or 240 Volt AC, 20 Amp, single phase, 60 Hz

electrical lighting, appliance, tool and motor loads.

Air Cleaner — Uses a dry type filter element and foam

pre–cleaner to limit the amount of dirt and dust sucked

into the engine.

Choke Lever — Used when starting a cold engine.

Circuit Breakers (AC) — Each receptacle is provided

with a "push to reset" circuit breaker 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.

Oil Fill Cap — Add oil to engine 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.

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 Receptacle

Fuel Tank

Choke Lever

Recoil Starter

Rocker Switch

Circuit

Breakers

(AC)

120/240 Volt AC,

20 Amp Receptacle

Air Cleaner

Grounding

Wing Nut

(not shown)

Oil Fill Cap

(not shown)

5,000 Watt Portable Generator

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 3).

2. Place the choke lever in the “Choke” position

(Figure 4).

3. Set the rocker switch to “On” position (Figure 5).

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 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 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 8.

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.

Fuel Valve is shown

in the On position

Figure 3 — FuelValve

Figure 4 — Choke Lever

Figure 5 — Rocker Switch

5,000 Watt Portable Generator

RECEPTACLES

This generator is equipped with the following receptacles:

120 Volt AC, 20 Amp Receptacle

This outlet is protected against overload by 20 Amp push-

to-reset circuit breakers.

Use each socket to operate 120 Volt AC, single phase,

60 Hz electrical loads requiring up to 2,400 watts (2.4kW)

of power at 20 Amps (Figure 6). Use cord sets that are

rated 125 Volts at 20 Amps (or greater).

120/240 Volt AC, 20 Amp Locking

Receptacle

Use a NEMA L14-20 plug with this receptacle. Connect a

4-wire cord set rated for 250 Volts AC at 20 Amps (or

greater).You can use the same 4-wire cord if you plan only

to run a 120 Volt load (Figure 7).

This receptacle powers 120Volt AC, single phase, 60Hz

loads requiring up to 2,400 watts of power (2.4 kW). Or it

will operate 240 Volt AC, single phase, 60Hz loads up to

4,800 watts (4.8 kW).This outlet is protected by 20 Amp

push-to-reset circuit breakers.

Figure 6 — 120Volt, 20 Amp Duplex Receptacle Figure 7 — 120/240 Volt AC, 20 Amp Receptacle

4-Wire Cord Set

240V

120V 120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-20 Ground (Green)

5,000 Watt Portable 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 8.

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

Planer/Jointer - 6” 1800 1800

Table Saw/Radial Arm Saw - 10” 2000 2000

Air Compressor - 1-1/2 HP 2500 2500

Figure 8 - Wattage Reference Chart

5,000 Watt Portable Generator

SPECIFICATIONS

Maximum Surge Watts . . . . . . . . . . . . . . . . .6,250 watts

Continuous Wattage Capacity . . . . . . . . . . .5,000 watts

Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0

Rated Maximum Continuous AC Load Current:

At 120 Volts . . . . . . . . . . . . . . . . . . . . . . .41.7 Amps

At 240 Volts . . . . . . . . . . . . . . . . . . . . . . .20.8 Amps

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase

Rated Frequency . . . . . . . . . . . . . . . . . . . . . . .60 Hertz

Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . 5 U.S. gallons

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . 158 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.

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

• 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.

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

•Do Not store gasoline from one season to another.

• 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 in clean and dry area.

5,000 Watt Portable Generator

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 8.

3. Contact Briggs and Stratton service

facility.

4. Contact Generac service facility.

Engine will not start;

or starts and runs

rough.

1. Rocker switch set to “Off”.

2. Dirty air cleaner.

3. Out of gasoline.

4. Stale gasoline.

5. Spark plug wire not connected to

spark plug.

6. Bad spark plug.

7. Water in gasoline.

8. Overchoking.

9. Low oil level.

10. Excessively rich fuel mixture.

11. Intake valve stuck open or closed.

12. Engine has lost compression.

1. Set switch to “On”.

2. Clean or replace air cleaner.

3. Fill fuel tank.

4. Drain gas tank and fill with fresh fuel.

5. Connect wire to spark plug.

6. Replace spark plug.

7. Drain gas tank; fill with fresh fuel.

8. Set choke to “Off” position.

9. Fill crankcase to proper level.

10. Contact Briggs and Stratton service

facility.

11. Contact Briggs and Stratton service

facility.

12. Contact Briggs and Stratton service

facility.

Engine shuts down

during operation.

1. Out of gasoline.

2. Fault in engine.

1. Fill fuel tank.

2. Contact Briggs and Stratton 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 8.

2. Replace air filter.

3. Contact Briggs and Stratton 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 until

engine runs smoothly.

2. Contact Briggs and Stratton service

facility.

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