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

DON'T OVERLOAD
G EN ERATO R
Capacity
You must make sure your generator cansupply enough
rated (running) and surge (starting) watts for the itemsyou
will power at the sametime. Follow these simple steps:
I. Select the itemsyou wilt 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 itemsrunning. SeeFigure 9.
3. Estimate how many surge (starting) watts you wilt
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 sametime, total
surge watts can be estimated by addingonly 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
800
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 lifeof your generator and attached devices,
it is important to take care when addingelectrical loadsto
your generator.There should be nothing connected to the
generator outlets before starting its engine.The correct
and safeway to managegenerator power isto sequentially
add loadsasfollows:
I. With nothingconnected to the generator, start the
engine asdescribed in this manual.
2. Plugin and turn on the first load,preferably the largest
loadyou 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 surgeloadsin generator capacity,
asdescribed above.
Tool or Appliance
Essentials
LightBulb - 75 watt
Deep Freezer
SumpPump
Refrigerator/Freezer - 18Cu. Ft.
Water Well Pump- I/3 HP
Heatin_Coolin_
Window AC - 10,000 BTU
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
SecuritySystem
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
Additional
Rated*
(Running) Surge
(Starting)
Watts Watts
75
500 500
800 1200
800 1600
1000 2000
1200 1800
300 600
800 1300
1000
1500
1500
2500
100
100
450
500
8O0
180
300
480 520
40O0
1000
600 1200
960 960
1000 1000
1500 1500
1800 1800
1800 1800
2000 2000
2500 2500
*Wattages listedare approximate only.Check toot or
appliancefor actual wattage.
/II

SPECIFICATIONS
Maximum SurgeWatts ................ I0,000 watts
Continuous Wattage Capacity ........... 8,000 watts
Power Factor .............................. 1.0
Rated Maximum Continuous AC Load Current:
At 120Volts ....................... 66.6Amps
At 240 Volts ....................... 33.3Amps
Phase................................. I-phase
Rated Frequency ....................... 60 Hertz
FuelTank Capacity................... 7 U.S.gallons
ShippingWeight ......................... 290 Ibs.
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on atimely
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 manualfor instructions.
CAUTION
Used motor oil hasbeen shown to cause skin cancer in
certain laboratory animals.
Thoroughly wash exposed areas with soap andwater.
KEEPOUT OF REACH OF CHILDREN. DON'T
POLLUTE.CONSERVERESOURCES.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 enginefuel system and causeproblems. In
addition, ifwater enters generator through cooling air slots,
some of the water wilt be retained in voidsand cracks of
the rotor and stator winding insulation.Waterand dirt
buildup on the generator internalwindings will eventually
decreasethe insulationresistance of these windings.
ENERATOR
WARNING
Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
Generator Cleaning
•Use a damp cloth to wipe exterior surfaces clean.
CAUTION
DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.
DO NOT insert any objects through cooling slots.
Use a soft bristle brush to loosen caked on dirt or oil.
Use a vacuum cleaner to pick up loose dirt and debris.
Use low pressure air (not to exceed 25 psi) to blow
away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.
I12

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,usethe following guidelinesto prepare it for
storage.
Generator Storage
•Clean the generator as outlined in"Generator Cleaning".
• Check that cooling air slots and openings on generator
are open and unobstructed.
WARNING
DO NOT place a storage cover over a hot generator.
Let equipment cool for asufficient time before placingthe
cover on the equipment.
Engine Storage
See engine owner's manualfor instructions.
Other Storage Tips
• To prevent gum from forming in fuel system or on
essential carburetor parts, add fuel stabilizer into fuel
tank and fill with fresh gasoline. Run the unit for several
minutes to circulate the additive through the carburetor.
The unit and fuel can then be stored for up to
24 months. Fuel stabilizer can be purchased locally.
• DO NOT store gasoline from one season to another
unless it has been treated as described above.
• 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 unit in a clean and dry area.
I13

TROUBLESHOOTING
Problem
No AC output is available, but
generator is running.
Cause
I. One of the circuit breakers is
open.
2. Fault in generator.
3. Poor connection or defective
cord set.
4. Connected device is bad.
Correction
I. Resetcircuit breaker.
2. Contact Authorized service
facility.
3. Check and repair.
4. Connect another device that is in
good condition.
I. Short circuit in a connected load. I. Disconnect shorted electrical
Generator runs good at no-load load.
but "bogs" down" when loads are 2. Generator is overloaded. 2. See "Don't Overload Generator".
connected. 3. Shorted generator circuit. 3. Contact Authorized service
facility.
Generator will not start; or starts Low oil level. Fill crankcase to proper level or place
and runs rough, generator on level surface.
I. Out of gasoline. I. Fill fuel tank.
Generator shuts down during
operation. 2. Low oil level. 2. Fill crankcase to proper level or
place generator on level surface.
Generator lacks power. Load is too high. See "Don't Overload Generator".
/14

NOTES
IIS

SCHEMATIC
66 77
FUSE 77
lO AHp J
13 _2_ra
_ _hYST_
EXCITATION
COIL
qk
CAPACITDR
POWER POWER
_INDING XINDING
_ BLK BLU
_i ENG
IGNITIDN
8 B
IIA
I
16

WIRING DIAGRAM
I17

g--s
EXPLODEDVIEW- MAIN UNIT
10
5
6\/\_ TO STARTER
61 \_TO + TERMINAL
ON BAWERY
72 18
/25
52 13 55
18 s2_ 55 /
51 /
56
77 /54
46
57
19 11 26
25
65
,mira 18

2- _r3
PARTS LIST- MAIN UNIT
Item Part # Description Item Part #
I NSP ENGINE 50 84794GS
2 BI89039GS CRADLE 51 47411GS
3 877304GS SUPPORT,Engine 52 22473GS
4 77816GS DECAL, Caution Hot Muffler 53 76040GS
5 93826GS DECAL, Start Instructions 54 84268GS
6 92982GS DECAL, Danger 55 JI89091GS
7 84363GS CAP,FuelTank 56 46476GS
8 48031CGS CLAMP,Hose 57 225| IGS
9 30340GS HOSE 58 22287GS
10 193633GS ASSY,Tank,Fuel 59 78289GS
(Includes Items 5,6 & 39) 60 77282GS
II 84135GS PIN 61 1892988GS
12 83465GS GROMMET,FueITank Mounting 62 22127GS
13 96832GS CLAMP,Cable 63 22097GS
14 23152GS SCREW 64 185939GGS
15 22237GS WASHER, Lock 65 187856GS
16 22241GS NUT 71 56893GS
17 75246GS SCREW 72 91526GS
18 55934GGS CLAMP,Hose 75 189286GS
19 J93074GS SUPPORT,HeatShleld 76 189155GS
20 189302AGS ASSY,Wire, Starter 77 187049GS
21 38353GS MOUNTS,Vibration 78 192280GS
23 22145GS WASHER
24 B4986GS DECAL, Ground
25 26850GS WASHER Items Not Shown
26 49820GS NUT, Nylok 189065GS
27 187104GS WASHER, Nylon MS5375
28 39287GS SCREW MS6497
29 B85586GS HANDLE (Includes Item 30) 193347GS
30 84605GS GRIP 807948
31 189051GS ASSY,Control Panel(see page21) 807595
32 82153GS SCREW 805812
34 73054GS DECAL, Fuel Shut-Off 392154
35 87680GS NUT,Wing 690661
36 45757GS SCREW 692056
37 49813GS NUT 692359
38 1955362|GS ASSY,Wire, Ground BB3061GS
39 192980GS KIT,Valve,Fuel 43438GS
43 52856GS NUT, Lock 37806GS
44 62265GS GROMMET 193634GS
45 27482GS WASHER
46 42907GS SCREW
47 22131GS WASHER
48 52618GS SCREW
49 49226GS WASHER, Lock
Description
GROMMET,Generator Cover
SCREW
WASHER
SCREW
ASSY,Alternator (seepage22)
SHIELD,Heat
CAP,Plug
SCREW
SCREW
BRACKET,Starter Switch
SWITCH, Starter
CABLE, B_ttery Positive
NUT
WASHER, Lock
CABLE, Battery Negative
KIT,Hardware Tray and Battery
SCREW
SCREW
SCREW
WASHER
PLUG, Domed
HOSE BARB
MANUAL, Owners
MANUAL, Engine
SHEET,Instruction
KIT,Battery Hardware
MUFFLER
CLAMP,M_er
BRACKET,Muffler
ARRESTOR,Spark
SCREW
BOLT
SCREW
OIL, Bottle
PLUG,240V,30A
PLUG, 125V,30A
KIT,Decal Service
Optional Accessories Not Included
84883GS Cord Wrap
43630GS 120/240 Volt AC 50 Amp Plug
19

2 ¸ _r3
EXPLODEDVIEWAND PARTS LIST-WHEEL KIT
10
/
4
Item
I
2
3
4
5
6
7
8
9
10
II
Part #
191267JGS
B4966GS
191265GS
22247GS
191413GS
22145GS
22413GS
39253GS
22129GS
B189085GS
192432GS
Description
AXLE
WHEEL
E_RING
WASHER
VIBE MOUNT, with Washer
WASHER
SCREW
SCREW
WASHER, Lock
LEG,Support
NUT, Lock
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