Generac Power Systems PowerBOSS Contractor 1648-0 Manuel utilisateur

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-por tables.corn

Model No. 1648-0 (4,500WattAC Generator) Manual No. 189264GS Revision5 (I 1/19/2002)

EQUIPMENT

DESCRIPTION

_Read this manual carefully and become familiar

with your generator. Know its applications, its

limitations and any hazards involved.

Thisgenerator isan engine-driven, revolving field,alternating

current (AC) generator. It was designedto supply electrical

power for operating compatible electrical lighting,appliances,

tools and motor loads.Thegenerator's revolvingfield is

driven at about 3,600rpm by a single-cylinderengine.

CAUTION! DO NOT exceed the generator's

wattage/amperage capacity.See"Don't Overload the

Generator" on page I I.

Everyeffort hasbeenmadeto ensurethat informationinthis

manualisaccurateand current However,Generacreserves

the right to change,alter or otherwise improvethe product

and this document at anytime without prior notice.

The EmissionControl Systemfor this generator iswarranted

for standardsset by the EnvironmentalProtection Agency.For

warranty informationrefer to the engineowner's manual.

SAFETY RULES

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

Obey all safety messages that follow this

symbol to avoid possible injury or death.

The safety alert symbol (_.) isusedwith a signalword

(DANGER, CAUTION,WARNING), a pictorial and/or a

safety messageto alert you to hazards.DANGER indicates

a hazardwhich, ifnot avoided,will result in death or serious

injury.WARNING indicatesa hazardwhich, if not avoided,

couldresult in death or serious injury.CAUTION

indicatesa hazardwhich, ifnot 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 messagesto

avoid or reduce the risk of injuryor death.

In the State of California a spark arrester isrequired by lawI

(Section 4442 of the California Public ResourcesCode). I

Other states may havesimilar laws.Federallawsapply on I

federal lands.If you equip the muffler with a spark arrester,

it must be maintained in effective working order.

WARNING

The engine exhaust from this product contains I

chemicals known to the State of California to cause

cancer, b rth defects, or other reproduct ve harm.

DANGER

Operate generator ONLY outdoors.

Keep at least 2 feet of clearance on all sidesof generator for

adequateventilation.

DO NOT operategenerator insideanybuildingor enclosure,

includingthe generator compartment of arecreationalvehicle(RV).

DANGER

National ElectricCode requires generator to be properly

grounded to an approved earth ground. Call an electrician for

local grounding requirements.

DANGER

When usinggenerator for backup power, notify utility

company.Use approved transfer equipment to isolate

generator from electric utility.

Use aground circuit fault interrupter (GFCI) in any damp or

highly conductive area,such asmetal 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 handsor feet are wet.

DO NOT allow unqualified persons or children to operate or

service generator.

ENERATOR

WARNING

Disconnect the spark plug wire from the spark plug and place

the wire where it cannot contact spark plug.

, WARNING

WHEN ADDING FUEL

Turn generator OFF and let it cool at least 2 minutes before

removing gascap.Loosen cap slowly to relieve pressure in tank.

Fill fuel tank outdoors.

DO NOT overfill tank.Allow spacefor fuel expansion.

Keep fuel awayfrom sparks,open flames,pilot lights, heat,and

other ignition sources.

DO NOT light a cigarette or smoke.

NHEN OPERATING EQUIPMENT

DO NOT tip engine or equipment at anglewhich causesfuel

to spill.

'HEN TRANSPORTING OR REPAIRING EQUIPMENT

Transport/repair with fuel tank EMPTYor with fuel shutoff

valve OFF.

Disconnect spark plug wire.

NHEN STORING FUEL OR EQUIPMENT WITH FUEL

IN TANK

Store awayfrom furnaces,stoves, water heaters,clothes

dryers or other appliances that havepilot light or other

ignitionsource becausethey can ignitefuel vapors.

DANGER

DO NOT allow any open flame,spark, heat,or lit cigarette

during andfor several minutes after charging a battery.

Wear protective goggles,rubber apron, and rubber gloves.

, WARNING

DO NOT touch hot surfaces.

Allow equipment to cool before touching.

CAUTION

DO NOT tamper with governedspeed.Generator supplies

correct rated frequency and voltage when running at governed

speed.

DO NOT modify generator in any way.

CAUTION

See"Don't Overload Your Generator" on page I h

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.

CAUTION

Use generator only for intended uses.

tf you have questions about intended use,ask dealer or

contact Generac.

Operate generator only on levelsurfaces.

DO NOT expose generator to excessive moisture, dust,dirt,

or corrosive vapors.

DO NOT insert any obiects through cooling slots.

tf connected devices overheat, turn them off and disconnect

them from generaton

Shut off generator if.'

-electrical output is lost;

-equipment sparks,smokes,or emits flames;

-unit vibrates excessively.

KNOWYOUR GENERATOR

Read this owner's manual and safety rules before operating your generator.

Compare the illustrationswith your generator, to familiarize yourself with the locationsof variouscontrols and

adjustments.Savethis manualfor future reference.

EngineSwitch Recoil Starter

FuelTank

Oil Fill

Air Cleaner

Choke Lever

120/240VoltAC,

30 Amp

Receptacle

Idle Control Switch

Spark Attester Muffler

Minder

Wing Nut 12Volt DC, 10Amp

Receptacle 120Volt AC, 20 Amp

Duplex Receptacles

Circuit

Breakers (AC)

12Volt DC, I0 Amp Receptacle -- Rechargea discharged

12Volt automotive type battery through this receptacle.

120Volt AC, 20 Amp GFCI Duplex Receptacles --

May be usedto supply electrical power for the operation

of 120Volt AC, 20 Amp, single phase,60 Hz electrical,

lighting,appliance,tool 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 to limit the

amount of dirt and dust suckedinto 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.

FuelTank -- Capacity of seven (7) U.S.gallons.

GroundingWing Nut -- Used for proper grounding of

unit (see page 7).

Maintenance Minder --Alerts you to change the oil and

service the air filter when needed.

Idle Control Switch --The idlecontrolruns the engineat

normal (high)speedswhen there isaloadpresent and runs

the engineat idle (low) speedswhen a load isnot present.

Oil Fill --Add engine oil here.

Recoil Starter-- Used to start the engine.

Engine 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.

ASSEMBLY

Your generator requires some assembly and isready 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.

Remove Generator From Carton

•Set the carton on a rigid fiat surfacewith "This Side Up"

arrows pointing upward.

• Carefully open the top flaps of the shippingcarton.

• Cut down corners at one end of carton from top to

bottom and laythat side of carton down fiat

• 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

The wheel kit isdesignedto greatly improvethe portability

of your generator.

NOTE: Wheel kit is not intendedfor over-the-road use.

You will need a socket wrench with I/2" or 13mm sockets

and a needle-nose pliers to install this kit.

Refer to Figure I and install the wheel kit as follows:

I. Placethe generator on a hard fiat surface.

2. Standat the engine end of the generator and gently tilt

the generator forward, high enough to placewooden

blocks beneath the cradle.This will allow you to add

the wheels.

Wheel

Axle /

Hex Nut

Support Leg

Vibration

_20mm

Cap Screw /

FlatWasher

Hex Nut

30mm Cap Screw

E-Ring

3. Slide the axle through the holes in the brackets

provided on the generator cradle.

4. Slide a wheel and fiat washer over the axle.

NOTE: Be sure to installboth wheels with the air

pressure valve on the outboard side.

5. Placethe e-ring onto the groove in the axle.

NOTE: Use retaining pins insteadof e-clip, if applicable.

6. Placeone 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.Seatthe e-ring by pressing the pliers closed.

7. Repeat step 4 through 6 to secure second wheel

Removethe wooden blocks.

8. Attach the vibration mounts to the support leg with

30mm capscrews,washers and lock nuts.

9. With the wheels on, you can now lift up the handle

end and attach the support leg with 20mm capscrews

and lock nuts.

10. Check eachfastener to ensure it issecure 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 hasbeen properly ftled with the recommended

oil may result in an engine failure.

To fill your engine with oil:

•Place generator on aJevel surface.

• Follow the oil grade recommendationsand oil fill

instructionsgiven in the engine owner's manual.

NOTE:The generator's revolving field rides on a

prelubricated and sealedbait bearing that requires no

additional lubrication for the life of the bearing.

Add Fuel

_ARNING! NEVERfillfuel tank indoors. NEVER

flit fuel tank whenengine isrunning 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 fuel with the generator

engine.DO NOT usepremium fuel. DO NOT mix oil

with fuel

• Clean areaaround fuel flit cap,remove cap.

• Slowly add unleaded regular fuel to fuel tank. Be careful

not to overfitLAliow about 1.5"of tank spacefor fuel

expansion (Figure2).

Fuel

..... N--N 22Nr

• Install fuel capand wipe up any spilled fuel.

IMPORTANT: It isimportantto prevent gum deposits

from forming in essentialfuel system parts,such asthe

carburetor, fuel filter, fuel hose or tank during storage.Also,

experience indicatesthat alcohol-blended fuels (called

gasohol,ethanol or methanol) can attract moisture, which

leadsto separation and formation of acids during storage.

Acidic fuel can damagethe fuel system of an enginewhile in

storage.

To avoid engine problems, the fuel system should be

emptied before storage of 30 claysor longer.See"Storage"

on page 13.NEVER use engine or carburetor cleaner

products in the fuel tank or permanent damagemay occur.

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 mayalso require proper grounding of the

unit. For that purpose, a GROUNDING WING NUT is

provided on the generator end (Figure 3).

Wing Nut

Generally,connecting a No. 12AWG (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 keepthe grounding wire attached after

connecting the stranded copper wire. However, local codes

may vary widely.Consult with a localelectrician for

grounding requirements in your area.

Properly grounding the generator helps prevent electrical

shock if aground fault condition exists in the generator or

in connected electrical devices,especiallywhen the unit is

equipped with a wheel kit. Proper grounding also helps

dissipate static electricity, which often builds up in

ungrounded devices.

OPERATING THE

G EN ERATO R

AAUTION! Never start or stop the engine with

electrical loadsconnected to 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).

Fuel Valve is shown

in the "On" position

Placethe chokelever in the "Closed" position

(Figure5).

Closed

Setthe engine switch to the "On" position (Figure6).

EngineSwitch

Off

Grasp the recoil handle and pull slowly until slight

resistance is felt.Then pull rapidly to start engine.

Move choke lever to "Open" 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 "Open" 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.Seeengine 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.

• Plugin and turn on the desired 120and/or 240 VottAC,

single phase,60 Hz electrical loads.

• DO NOT connect 240Vott loads to the 120Volt duplex

receptacles.

• DO NOT connect 3-phase loads to the generator.

• DO NOT connect 50 Hz loadsto the generator.

•DO NOT OVERLOADTHE GENERATOR. See

"Don't Overload the Generator" on page I I.

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 the engine switch to "Off' position.

• Move the fuel valve to the "Off' position.

Operating Automatic Idle Control

This switch isdesignedto greatly improve fuel economy.

When this switch is turned ON, the engine will only

run at its normal high governed engine speed when an

electrical load is connected.When an electrical load is

removed,the enginewill run at a reduced speed.With the

switch off, the engine will run at the normal high engine

speed.Always have the switch off when starting and

stopping the engine.

Charging a Battery

_ ARNING! Storage batteries give off explosive

hydrogen gaswhile recharging.An explosive mixture

will remain around the battery for a long time after

it hasbeen charged.The slightest spark canignite

the hydrogen and causean explosion, resulting in

blindness or other serious injury.

_ARNING! DO NOT permit smoking,open

flame,sparks or anyother source of heat around a

battery.Wear protective goggles,rubber apron and

rubber gloves when working around a battery.

Battery electrolyte fluidis an extremely caustic

sulfuric acid solution that can causesevere burns. If

spill occurs flush area with clear water immediately.

Your generator hasthe capability of recharging a discharged

12Volt automotive or utility style storage battery. DO

NOT use the unit to chargeany 6Volt batteries. DO NOT

usethe unit to crank an engine havinga discharged battery.

To recharge 12Volt batteries, proceed as follows:

• Check fluidlevel in all battery cells.If necessary,add

ONLY distilled water to cover separators in battery cells.

DO NOT use tap water.

• If the battery isequipped with vent caps,make sure they

are installed and are tight.

• If necessary,clean battery terminals.

• Connect battery charge cable connector plug to panel

receptacle identified by the words "12-VOLTS D.C".

• Connect battery charge cable clamp with red handle to

the positive (+) battery terminal (Figure7).

12 VOLT D.C.

RECEPTACLE

POS NEG

12 VOLT BA'n'ERY

• Connect battery charge cable clamp with black handle

to the negative (-) battery terminal (Figure7).

• Start engine.Let the engine run while battery recharges.

• When battery hascharged,shut down engine

NOTE: Use an automotive hydrometer to test battery state

of chargeand condition. Follow the hydrometer

manufacturer'sinstructions carefully.Generally,a battery is

consideredto be at 1(30°/ostateof chargewhen specificgravity

of its fluid (asmeasuredby hydrometer) is 1.260or higher.

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 8).You can usethe same 4-wire cord if you

)lan to run a 120Volt load.

4-WireCord Set

(Neutral)

Y(Hot) | X (Hot)

NEMA L14-30 /--_ Ground(Green)

This receptacle powers 120/240Volt AC, 60 Hz,single

phaseloads requiring up to 4,500 watts of power (4.5 kW)

at 30 Amps for 120Volts or 240Volts.The outlet is

protected bya push-to-reset circuit breaker.

_CAUTION! Although this outlet states it has a

120/240 Volt 30 Amp rating (up to 7,200 watts), the

generator is only rated for 4,500 watts. Powering

loads that exceed the wattage/amperage capacity of

the generator can damage it or cause serious

injuries.

120 Volt AC, 20 Amp, GFCI Duplex

Receptacles

Eachduplex receptacle (Figure 9) isprotected against

overload by a push-to-reset circuit breaker.

•11 I

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 loads at 20Amps (or greater).

Ground Fault Protection

Thisunit isequipped with a Ground Fault Circuit

Interrupter (GFCI).This device meets applicablefederal,

state and localcodes.

The GFCI protects againstelectrical shock that may be

caused ifyour body becomes a path which electricity

travels to reach ground.This could happenif you touch a

"Live" applianceor wire, or are touching plumbing or other

materials that connect to the ground.

When protected by a GFCI, one may still feel a shock, but

the GFCI should cut current off quickly enough so that a

person in normal health should not suffer anyserious

electrical injury.

_CAUTION!The GFCI will not protect you

against the following situations: (I) Line-to-line

shocks;(2) Current overloads or line-to-lineshort

circuits.The fuse or circuit breaker at the

distribution panel must provide such protection.

Testing the GFCI

Test your GFCI outlet every month, asfollows:

• Pushthe black*'Test" button.The red "Reset" button

should pop out, which should allow no power to reach

the outlet. Use a test lamp in eachoutlet to test this. I[o_ IIP_LV_ilDZeelIJ[!]r_]:i _tI

_AUTION! Ifthe"Reset" button does not pop

out or the test tamp remains lit when the "Reset"

button ispopped out, do not useany outlets on the

circuit Call a qualified electrician.

• If the GFCI tests good, restore power by pressingthe

"Reset" button firmly until it isfully in place and locksin

that position. If the GFCI outlet does not reset

properly, do not use the outlet _call a Generac

service center.

• If the GFCI trips by itselfat anytime, reset and test the

outlet. If the reset button does pop out when the

test button is pressed, do not use the outlet. Call

a Generac service center.

12Volt DC, I 0 Amp Receptacle

This receptacle (Figure10) allows you to recharge a 12Volt

automotive or utility style storage battery with the battery

chargecables provided.

This receptacle can not recharge 6Volt batteries and can

not be used to crank an engine havinga discharged battery.

See"Charging a Battery" on page8 before attempting to

recharge a battery.This outlet isprotected by a l0 Amp self

resetting circuit breaker.

/10

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