Generac Portable Products 1652-0 User manual

Owner's Manual
". | _,
Generator
Wheel kit
Engine oil
Locking 20 Amp plug
Locking 30 Amp plug
Owner's manual
Engine manual
If any parts are missing or damaged, call 1-800-270-1408.
SafetyRules.................................... 2-3
Assembly...................................... 4-5
Know Your Generator ............................. 6
Operation ..................................... 7-9
Product Specifications............................. 10
Maintenance.................................... I0
Storage........................................ I0
Notes ...................................... I 1-12
Troubleshooting ................................. 13
Schematic...................................... 14
Wiring Diagram ................................. 15
Replacement Parts............................. 16-19
Warranty ................................. Last Page
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
This isthe 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.

EQUIPMENT
DESCRIPTION
This generator 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.
This manualcontains information for a generator that
operates 120 and/or 240Volt, single phase,60 Hz devices
that require up to 4,200 watts (4.2 kW) of power that pull
up to 35Amps at 120Volts or 17.5Amps at 240Votts
CAUTION! Do Not exceed the generator's
wattage/amperage capacity.Add up the rated watts of all
devices you are connecting to generator receptacles at one
time.This total should not be greater than 4,200 watts. See
"Don't Overload the Generator" on page 9.
The generator's revolving field is driven 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
This generator 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.
or other re
_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.
_DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. If breathed in
sumcient concentrations, carbon monoxide
can cause unconsciousness or death. Operate
this equipment outdoors where adequate ventilation
is available.

• The generator produces avery powerful voltage that can
cause serious injuryor 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 injuryfrom 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 spilling gasolineon a hot engine.Comply
with all laws regulating storage and handlingof gasoline.
•Do Not overfitl 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).
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 brassgrounding rod
(electrode) provides adequateprotection againstelectrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, locat codes
may vary widely.Consult with a local electrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock ifa 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.

Yourgeneratorrequiressomeassemblyandisreadyfor
useafterit hasbeenproperlyservicedwiththe
recommendedoilandfuel.
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 wilt result in an
engine failure.
REMOVE G EN ERATOR
FROM CARTON
•Set the carton on a rigid flat surface with "This Side Up"
arrows pointing upward.
• Carefully open the top flaps of the shippingcarton.
• Cut clown 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.
INSTALL WHEEL KIT
The wheel kit isdesignedto greatly improvethe portability
of your generator.
NOTE:Wheel kit isnot intendedfor over-the-road use.
You will need a socket wrench with I/2" or 13mm sockets
and a needle+nosepliers to installthis kit.
Refer to Figure 2 and install the wheel kit as follows:
• Placethe generator on a hard flat surface.
• Standat the engine end of the generator andgently tilt
the generator forward, high enough to placewooden
blocks beneath the cradle.This will allow you to add the
wheels.
• Slide the axle through the holes in the brackets provided
on the generator cradle.
• Slide a wheel and fiat washer on one end of the axle.
Make sure the air inflation valve isoutward. Insert the
retaining pin.
• Slide the axle through until wheel is tight againstbracket.
Axle Wheel
Washer
Lock Nut_
Support
Vibration Mount_
Capscrew /
Retaining Pin
30mm Capscrew_ Lock Nut

• Slidetheotherwheelandfiatwasherontheotherend
oftheaxle.Makesuretheairinflationvalveisoutward.
Inserttheretainingpinusingtheneedle-noseplier.
Removethewoodenblocks.
• Attachthevibrationmountstothesupportlegwith
30mmcapscrews,washersandlocknuts.
• Withthewheelson,youcannowtlftupthehandleend
andremovetheexistinghardwarefromtheleftunit
vibrationmountwitha13mmwrench.Usethesame
hardwaretoattachthesupportleg.
• Attachtheothersideofthesupportlegwitha20mm
capscrewandlocknut
• Checkeachfastenertoensureitissecureandthetires
areinflatedbetween15-40PSL
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! Any attempt to crank or start the engine
before it hasbeen properly filled with the recommended
oil may result in an engine failure.
To fill your engine with oil:
• Placegenerator on a levelsurface.
•Followthe oilgrade recommendations andoil fill
instructionsgiven inthe engine owner's manual.
NOTE= The generator's revolving field rides on a
prelubricated and sealedball bearing that requires no
additional lubricationfor the life of the bearing.
A 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 area around fuel fill cap,remove cap.
• Slowly add unleaded regular gasolineto fuel tank. Be
careful not to overfill.Allow about 1.5"of tank spacefor
fuel expansion (Figure 3).
Fuel
N--NC22N.
• 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 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 10. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
Add Gasoline
AARNING! 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.

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. Savethis manualfor future reference.
EngineSwitch
Oil Fill Cap Recoil Starter FuelTank
Circuit Breakers (AC)
\
120Volt AC, 30 Amp
Receptacle
Air Cleaner
120/240Volt AC,
20 Amp Receptacle SparkArrester Muffler
120Volt AC, 20 Amp
Duplex Receptacle
Grounding Wing Nut
120Volt AC, 20 Amp Duplex Receptacle -- May be
usedto supplyelectrical power for the operation of
120Volt AC, 20Amp, single phase,60 Hz electricallighting,
appliance,tool and motor loads.
120Volt AC, 30 Amp Locking Receptacle -- May be
used to supply electrical power for the operation of
120Volt AC, 30 Amp, single phase,60 Hz electrical lighting,
appliance,toot and motor loads.
120/240 Volt AC, 20 Amp Locking Receptacle -- May
be usedto supply electrical power for the operation of
120and/or 240Volt AC, 20 Amp, single phase,60 Hz
electrical lighting,appliance,tool and motor loads.
Air Cleaner -- Usesa 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) -- Eachreceptacle is provided
with a "push to reset" circuit breaker to protect the
generator againstelectrical overload.
FuelTank -- Capacity of seven (7) U.S.gallons.
GroundingWing Nut -- Used for proper grounding of
unit.
Oil Fill Cap --Add oil to engine here.
Recoil starter -- Used to start the engine.
Engine Switch -- Setthis switch to "On" before using
recoil starter. Setswitch to "Off' to switch OFF engine.
Spark Arrester Muffler- Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.

OPERATING THE
GENERATOR
ACAUTION! Never start or stop unitwithelectrical loadsconnected AND with the connected
devicesturned ON.
Starting the Engine
Disconnect all electrical loadsfrom the generator. Follow
these start instructionsteps in numerical order:
I. Turn the fuel valveto the "On" position (Figure 4).
FuelValveisshown
in the "On" position
2. To start a cold engine,move the choke leverto the
"CLOSED" position.To restart a warm engine,leave
the choke lever inthe "OPEN" position (Figure 5).
Closed
3. Set the engine switch to the "ON" position (Figure6).
Engine Switch
4. Grasp starter grip and pull slowly untilyou feel some
resistance.Then pull cord out with rapid full arm
stroke. Let rope return slowly. Do Not let rope
"snap back" against starter.
5. If the choke lever hasbeen moved to the"CLOSED"
position to start the engine,gradually move it to the
"OPEN" position asthe enginewarms up.
NOTE= If engine still fails to start after 3 pulls,check for
proper oil level in crankcase.This unit isequipped with a
low oit device.See engine manual.
Refer to the engine owner's manual for complete
starting instructions.
Connecting Electrical Loads
•Let engine stabilize and warm upfor a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 VottAC,
singlephase,60 Hz electrical loads.
•Do Not connect240Volt loadsto the 120Volt duplex
receptacles.
•Do Not connect 3-phase 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 loadsfrom 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 internaltemperatures of engine andgenerator.
• Move engine switch to "OFF" position.
• Move the fuel valve to the "OFF" position.

RECEPTACLES
120 Volt AC, 20 Amp, Duplex
Receptacle
Eachreceptacle (Figure 7) isprotected againstoverload by
a 20Amp push-to-reset circuit breaker.
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 20 Amps (or greater).
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect a
3+wire cord set rated for 125VoltsAC at 30Amps to the
plug (Figure 8).
3-Wire Cord Set NEMA L5-30
Neutral
120V
Hot
Ground (Green)
Usethis receptacle to operate 120VoltAC, 60 Hz, single
phaseloadsrequiring up to 3,600 watts (3.6 kW) of power
at 30Amps.The outlet isprotected by a 30Amp
push-to-reset circuit breaker.
120/240 Volt AC, 20 Amp Locking
Receptacle
Use a NEMA LI4-20 plug with this receptacle. Connect a
4-wire cord set rated for 250Volts at 20 Amps (or greater)
(Figure 9).You can usethe same4-wire cord ifyou plan to
run a 120Vott load.
4-Wire Cord Set
' (Neutral)
Y (Hot) X (Hot)
NEMA L14-20 Ground (Green)
This receptacle powers 120/240Volt AC, 60 Hz, single
phaseloads requiring up to 2,400 watts of power at
20 Amps for 120Volts; 4,200 watts of power (4.2 kW) at
17.5Amps for 240 Volts.The outlet isprotected by a
20 Amp push-to-reset circuit breaker.
_CAUTION! Although this outlet israted for
240 Volt 20 Amp (up to 4,800 watts), the generator
isonly rated for 4,200 watts. Powering loads that
exceed the wattage/amperage capacity of the
generator can damageit or causeserious injuries.
240 Volt loads powered through this outlet should
not exceed 17.5Amps of current draw.
I:I

DON'T OVERLOAD YOU R
GENERATOR
Capacity
You must make sure your generator cansupply enough
rated (running) and surge (starting) watts for the itemsyou
wilt power at the same time. Follow these simple steps:
I. Select the items you will power at the same time.
2. Total the rated (running) watts of these items.Thisis
the amount of power your generator must produce to
keep your items running.SeeFigure IO.
3. Estimate how many surge (starting) watts you will
need.Surge wattage isthe short burst of power
needed to start electric motor-driven tools or
appliancessuch asa circular saw or refrigerator.
Becausenot 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:
Tool or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Rated (Running)
Watts
1200
8OO
500
500
75
3075 Total
Running Watts
Total Rated (Running)Watts = 3075
Highest Additional SurgeWatts = 1800
Total Generator Output Required = 4875
Additional Surge
(Starting) Watts
1800
1600
500
1800 Highest
SurgeWatts
Power Management
To prolong the life of your generator and attached devices,
it isimportant to take care when addingelectrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it'sengine.The correct
and safeway to managegenerator power isto sequentially
add loads asfollows:
I. With nothingconnected to the generator, start the
engine asdescribed in this manual.
2. Plugin 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 loadsthan the generator capacity.Take
specialcare to consider surgeloads ingenerator capacity,
asdescribed above.
Tool or Appliance
Essentials
LightBulb - 75 watt
Deep Freezer
SumpPump
Refrigerator/Freezer - 18Cu. Ft.
Water Well Pump- I/3 HP
Heating/Cooling
Window AC - 10,000BTU
Window Fan
FurnaceFanBlower - I/2 HP
Kitchen
Microwave Oven - 1000Watt
Coffee Maker
Electric Stove - SingleElement
Hot Plate
Family Room
DVD/CD Player
VCR
Stereo Receiver
Color Television - 27"
Personal Computer w/I 7" monitor
Other
Security System
AM/FM Clock Radio
GarageDoor Opener - I/2 HP
Electric Water Heater - 40 Gallon
DIY/Job Site
Quartz Halogen Work Light
Airless Sprayer - I/3 HP
Reciprocating Saw
Electric Drill - I/2 HP
Circular Saw- 7 I/4"
Miter Saw- I0"
Table Planer - 6"
Table Saw/RadialArm Saw- I0"
Air Compressor - I-I/2 HP
Rated*
(Running)
Watts
75
500
8O0
8O0
1000
12O0
3OO
8O0
1000
1500
1500
25O0
Additional
Surge
(Starting)
Watts
500
1200
1600
20O0
1800
6O0
1300
100
100
450
5o0
8o0
18o
3O0
480 520
40O0
1000
600 1200
960 960
1000 1000
1500 1500
1800 1800
1800 1800
2000 2000
2500 2500
*Wattages listed are approximate only. Check toot or
appliance for actual wattage.

SPECIFICATIONS
MaximumSurgeWatts ................. 5,250 watts
Continuous Wattage Capacity ........... 4,200 watts
Power Factor .............................. 1.0
Rated Maximum Continuous AC Load Current:
At 120Volts ......................... 35 Amps
At 240 Volts ....................... 17.5Amps
Phase................................. I-phase
Rated Frequency ....................... 60 Hertz
FuelTank Capacity................... 7 U.S.gallons
ShippingWeight ......................... 175 Ibs.
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
Seeengine owner's manualfor instructions.
AAUTION! 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 soapand water.
KEEPOUT OF REACH OF CHILDREN. DON'T
POLLUTE.CONSERVERESOURCES.RETURN
USED OILTO COLLECTION CENTERS.
Generator Maintenance
Generator maintenanceconsists 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 anycorrosive vapors.Cooling air
slots in the generator must not become clogged with
snow, leavesor anyother foreign material.
NOTE: Do Not usea garden hose to cleangenerator.
Water canenter 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 awaydirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.
STO RAG E
The generator should be started at least once every seven
claysand 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 asoutlined in "To Clean the
Generator"
• Check that cooling air slots and openingson generator
are open and unobstructed.
ACAUTION! Storage covers can be flammable.
Do Not place a storage cover over ahot
generator. Let the unit coot for a sufficient time
before placingthe cover on the unit.
Engine Storage
Seeengine owner's manualfor instructions.
Other Storage Tips
•Do Not store gasoline from one season to another.
• Replace fuel container if it starts to rust. Rust andlor dirt
in fuel can cause problems if it's used with this unit.
• Store in clean and dry area.