Generac Power Systems PowerBOSS 8000 PowerMaster User manual

TM
WATTS TM
Portable Generator Owner's Manual
Questions? Help is just a moment away! I!!!!! !!![1[11
Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com 0 9
Model No. 1647-0 (8,000 Watt AC Generator) Manual No. 189065GS Revision 4 (08/08/2003)

TABLE OF CONTENTS
SafetyRules.................................. 2-4
Know Your Generator ........................... 5
Assembly.................................... 6-7
Operation .................................. 8-I1
Maintenance.................................. 12
Storage...................................... 13
Troubleshooting ............................... 14
Notes ....................................... 15
Schematic/Wiring Diagram .................... 16-17
Replacement Parts........................... 18-22
Warranty .................................... 23
EQUIPMENT
DESCRIPTION
_Read this manual carefully and become familiar
with your generator. Know its applications, its
limitations and any hazards involved.
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.Thegenerator's
revolving field is driven at about 3,600rpm by the engine.
CAUTION! DO NOT exceed the generator's
wattage/amperagecapacity.See"Don't Overload
Generator" on page I I.
Every effort hasbeen madeto ensure that informationin
this manualis accurate and current. However, we reserve
the right to change,alter or otherwise improve the product
and this document at anytime without prior notice.
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.
In the State of California a spark arrester is required by lawJ
(Section 4442 of the California PublicResourcesCode).
Other states may havesimilar laws.Federallawsapply on
federal lands.If you equip the muffler with a spark arrester,
it must be maintained in effective working order.
SAFETY RULES
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.
The safety alert symbol (_.) isused with a signalword
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety messageto alert you to hazards.DANGER indicates
a hazard which, if not avoided,will result in death or
serious injury. WARNING indicatesa hazardwhich, if not
avoided,could result in death or serious injury.
CAUTION indicatesa hazardwhich, if not avoided,might
result in minor or moderate injury. CAUTION, when used
without the alert symbol, indicatesa situation that could
result in equipment damage.Follow safety messagesto
avoid or reduce the risk of injury or death.
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.
Hazard Symbols and Meanings
Electrocution Electrical Shock Electrical Shock
Toxic Fumes
Explosive Pressure
Explosion Fire
Chemical Burn Hot Surface
/2

DANGER
Operate generator ONLY outdoors.
Keepat least 2 feet of clearance on all sidesof generator for
adequate ventilation.
DO NOT operategenerator insideanybuildingor enclosure,
includingthe generator compartmentof arecreationalvehicle(RV).
DANGER
When usinggenerator for backup power, notify utility
company.Use approved transfer equipment to isolate
generator from electric utility.
Use a ground fault circuit interrupter (GFCi) in anydamp 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
inwater, while barefoot, or while handsor feet are wet.
DO NOT allow unqualified persons or children to operate or
service generator.
DANGER
DO NOT allow any open flame,spark, heat,or lit cigarette
during and for several minutes after charging a battery.
Wear protective goggles,rubber apron, and rubber gloves.
, WARNING
WHEN ADDING FUEL
Turngenerator OFF and let it cool at least 2 minutes before
removing gascap.Loosen cap slowly to relieve pressure in tanlc
Fill fuel tank outdoors.
DO NOT overfill tank.Allow spacefor fuel expansion.
Keep fuel awayfrom sparks,open flames,pilot lights, heat,and
other ignitionsources.
DO NOT light a cigarette or smoke.
eVHEN OPERATING EQUIPMENT
DO NOT tip engine or equipment at angle which causesfuel
to spill.
Thisgenerator isnot for use in mobile equipment or marine
applications.
'HEN TRANSPORTING OR REPAIRING EQUIPMENT
Transportlrepair with fuel tank EMPTY or with fuel shutoff
valve OFE
Disconnect spark plug wire.
_HEN STORING FUEL OR EQUIPMENT WITH FUEL
IN TANK
Store awayfrom furnaces, stoves, water heaters, clothes
dryers or other appliancesthat have pilot light or other
ignition source becausethey can ignite fuel vapors.
, WARNING
Thisgenerator does not meet U. S.Coast Guard Regulation
33CFR-183 and should not be used on marine applications.
Failure to use the appropriate U. S.Coast Guard approved
generator could result in bodily iniury and/or property
damage.
mm_mm 3

WARNING
;ENERATOR
Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
, WARNING
DO NOT touch hot surfaces.
Allow equipment to cool before touching.
CAUTION
DO NOT tamper with governed speed.Generator supplies
correct rated frequency and voltage when running at governed
speed.
DO NOT modify generator in any way.
CAUTION
See"Don't Overload Generator" on page I I.
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 onlyfor intended uses.
tf you have questions about intended use,askdealer or call
1-800-270-1408.
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.
tf connected devices overheat, turn them off and disconnect
them from generatoc
Shut off generator if.'
-electrical output is lost;
-equipment sparks,smokes,or emits flames;
-unit vibrates excessively.
/4

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.
Fuel Tank Choke Lever
Circuit Breakers (AC)
\Recoil Starter
OnlOff Switch
120/240 Volt AC,
30Am
.'leaner
Receptacle
Grounding Fastener
120Volt AC, 20 Amp
Duplex Receptacle
120 Volt AC, 20 Amp, Duplex Receptacle -- May be
used to supply electrical power for the operation of
120Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120 Volt 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, tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle -- May
be used to supply electrical power for the operation of
120 andlor 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.
1201240 Volt AC, 50 Amp Receptacle -- May be used
to supply electrical power for the operation of 1201240Volt
AC, 50 Amp, single phase, 60 Hz electrical loads.
SparkArrester Muffler
120/240Volt AC,
50 Amp Receptacle
Air Cleaner -- Uses a dry type filter element and foam
pre-cteaner 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.galtons.
Grounding Fastener -- If required, pleaseconsult a
qualified electrician, electrical inspector, or the local agency
havingjurisdiction.
On/Off Switch -- Setthis switch to "On" before starting
unit. Set switch to "Off' to shut clown the engine.
Recoil starter -- Used to start the engine.
Spark Arrester Muffler -- Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.
/5

ASSEMBLY
Your generator requires some assemblyand 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 palteted carton on a rigid flat surface.
• Carefully cut bandsaround the shipping carton.
• Lift carton off the generator.
• Remove all packing material, carton fillers, etc.
• Remove the generator from the shipping pallet.
Carton Contents
Check all contents. If any parts are missingor damaged,call
the generator helpline at 1-800-270-1408.
The generator
Electric start battery cables
Generator and engine owner's manuals
Locking 30Amp plugs
Battery mounting bracket/hardware
2 bottles engine oil
Wheel kit
INSTALL WHEEL KIT
NOTE: Wheel kit isnot intendedfor over-the-road use.
To installyour wheel kit, you need the following toot:
• Socket wrench with I/2" or 13mm sockets.
• Neddle-nose pliers
InstallWheel Kit as follows: (SeeFigure I)
I. Placegenerator on a hard flat surface.
2. Standat control panel end of generator and gently tilt
generator up,high enough to placewooden blocks
beneath cradle.This will allow you to add wheels.
3. Slide axle through holes in brackets provided on
generator cradle.
4. Slide a wheel spacer,wheel and flat washer on one end
of axle. Make sure air inflationvalve isoutward. Place
e-ring onto groove in axle.
5. Placeone end of needle nose pliers on bottom of axle
and other end of pliers on top of e-ring.Seate-ring by
pressing pliers closed.
6. Slideaxlethrough until wheel istight againstbracket.
7. Install e-ring on other side in same manner as steps4
& 5. Removewooden blocks.
8. Attach vibration mounts to support leg with a 30mm
capscrew and lock nut.
J
Wheels
J
Locknut
Flatwasher
/Vibration
_ Mount --
E-Ring
,_port Leg
_-- Flatwasher
__ Lockwasher
30mm _ 20mm
-Capscrew Capscrew
/6

9. Withwheelson,securesupportlegassemblytocradle
with20mmlongcapscrews,flatwashers,andlock
washers.
10.Checkeachfastenertoensureitissecureandtires
areinflatedbetween15-40PSI.
INSTALLING BATTERY
NOTE: The generator canbe started manually.If you
choose not to use the electric start feature of this
generator, you do not need to install the battery.
_AUTION! If battery is not installed,DO NOT
operate engine without insulatingthe red positive
battery cable with electrical tape, or it could blow a
fuse and causesparks.
We recommend you purchase and install a Briggs &
Stratton 12Volt DC battery (Group U I;Type GT-X).The
battery should be serviced with electrolyte fluid and fully
charged prior to installation.
Install the battery as follows:
I. Find battery fasteners shipped loosein carton.
2. Set battery onto tray.
3. Retainbattery to tray with one battery hold down
bracket,two Jbolts,two fiat washersandtwo hex nuts
(Figure2).
4. Connect red battery cablefrom engine starter switch
to positive (+) terminal on battery with bolt, washer
and nut (Figure2).
5. Connect black battery cable to negative (-) terminal
on battery with bolt, washer and nut (Figure 2).
6. Double check all connections to ensure they are in
correct locations and secure.
BEFORE STARTING THE
ENGINE
Add Engine Oil and Fuel
•Place generator on a level surface.
• Refer to engine owner's manualand follow oil and fuel
recommendations and instructions.
CAUTION
•Refer to engine manualfor oil andfuel fill information.
• Damage to equipment resulting from failure to follow this
instructionwill void warranty.
NOTE: Check oil often during engine break-in. Refer to
engine owner's manualfor recommendations.
NOTE: The generator assembly rotates on a pretubricated
and sealed ball bearing that requires no additional
lubricationfor the life of the bearing.
/7

USING THE GENERATOR
System Ground
The generator hasa systemground that connects the
generator frame components to the ground terminals on
the AC output receptacles.The systemground is connected
to theAC neutral wire (the neutral is bonded to the
generator frame).
Special Requirements
There may be Federalor State Occupational Safetyand
Health Administration (OSHA) regulations,localcodes,or
ordinances that apply to the intendeduseof the generator.
Pleaseconsult a qualified electrician, electrical inspector,or
the localagencyhavingjurisdiction.
•In some areas,generators are required to be registered
with localutilitycompanies.
• If the generator isusedat a construction site,there may
be additional regulations which must be observed.
Connecting to a Building's Electrical
System
Connections for standby power to a buitding's electrical
system must be made by a qualified electrician.The
connection must isolate the generator power from utility
power, and must comply with all applicablelawsand
electrical codes.
DANGER
When usinggenerator for backup power, notifyutility
company.Use approved transfer equipment to isolate
generator from electric utility.
Use a ground fault circuit interrupter (GFCI) in anydamp 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
inwater, while barefoot, or while handsor feet are wet.
DO NOT allow unqualified persons or children to operate or
service generator.
OPERATING THE
G EN ERATO R
CAUTION
See"Don't Overload Generator" on page I I.
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.
Starting the Engine
Disconnect altelectrical loadsfrom the generator. Use the
following start instruction steps by numerical order:
I. Make sure unit is on a levelsurface.
IMPORTANT: Failureto start and operate unit on a level
surface will causethe unit not to start or shut down during
operation.
2. Turn the fuel valve to the "On" position (Figure 3).
Fuel Valve is shown
in the On position
3. Follow start instructions given in engine owner's
manual.
NOTE: If engine starts after 3pulls but fails to run, or if
unit shuts down during operation, make sure unit is on a
level surface and check for proper oil level in crankcase.
This unit may be equipped with a low oil protection device.
See engine manual.
Connecting Electrical Loads
• Let engine stabilize and warm upfor a few minutes after
starting.
• Plug in and turn on desired 120 and/or 240VottAC,
singlephase,60 Hz electrical loads.
/8

• DO NOT connect 240Volt loads to 120Volt receptacles.
• DO NOT connect 3-phase loads to generator.
• DO NOT connect 50 Hz loadsto generator.
•DO NOT OVERLOADTHE GENERATOR. See
"Don't Overload Generator" on page 1I.
Stopping the Engine
I. Unplug all electrical loads from generator panel
receptacles.NEVER start or stop engine with electrical
devices plugged in and turned ON.
2. Let engine run at no-load for several minutes to
stabilize internal temperatures of engine and generator.
3. Turn engine off according to instructions given in the
engine owner's manual.
4. Move fuel valve to "Off" position.
COLD WEATH ER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high clew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.
Build a structure that will enclose three sides and the top
of the generator:
I. Make sure entire muffler-side of generator is exposed.
Note that your generator mayappear different from
that shown in Figure 4.
2. Ensurea minimum of two feet clearance between open
side of box and nearest object.
3. Faceexposed end away from wind and elements.
4. Enclosure should hold enough heat created by
generator to prevent problems.
_, DANGER
Operate generator ONLY outdoors.
Keep at least 2 feet of clearance on all sides of generator for
adequate ventilation.
DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).
Remove generator from shelter when temperature is above
40°F [4°C].
RECEPTACLES
_, CAUTION
NEVER attempt to power a device requiring more
amperagethan generator or receptacle can supply.
DO NOT overload the generator. See"Don't Overload
Generator".
120/240 Volt AC, 50 Amp Receptacle
Use a NEMA 14-50 plug with this receptacle (Figure5).
Connect a 4-wire cord set rated for 250Volt AC loads at
50 Amps to the plug.
F
Y(Hot)
_240 Volts AC
rame Ground
X (Hot)
W (Neutral)
NEMA 14-50
I9

Usethisreceptacletooperate240VoltAC,60Hz,single
phaseloadsrequiringupto8,000watts(8.0kW)ofpower.
Theoutletisprotectedbya35Amppush-to-resetcircuit
breaker.
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 6).You can usethe same 4-wire cord if you
)lanto run a 120Volt load.
4-Wire Cord Set
i
f
(Neutral)
Y(Hot) | X (Hot)
NEMA L14-30 /_ Ground(Green)
This receptacle powers 1201240Volt AC, 60 Hz,single
phase loads requiring up to 3,600 watts of power at
30 Amps for 120Volts;7,200 watts of power (7.2 kW) at
30 Amps for 240Volts.The outlet isprotected bya 30 Amp
push-to-reset circuit breaker.
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect a
3-wire cord set rated for 125Volt AC loads at 30 Amps to
the plug (Figure 7).
_ire Cord Set NEMA L5-30
Neutral
120V
Hot
Ground (Green)
Usethis receptacle to operate 120VoltAC, 60 Hz, single
phaseloads requiring up to 3,600 watts (3.6 kW) of power
at 30Amps.The outlet is protected by a 30Amp
push-to-reset circuit breaker.
120 Volt AC, 20 Amp, Duplex
Receptacle
Eachreceptacle (Figure8) isprotected against overload by
a 20 Amp push-to-reset circuit breaker.
Use each receptacle to operate 120Volt AC, single-phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20Amps of current. Usecord sets that are rated for
125Volt AC loads at 20Amps (or greater).
i10