Generac Power Systems PowerBOSS Contractor 1648-0 User manual

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.
/2

, 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.
/3

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.
/4

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
/5

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.
/6

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
2.
.
4.
5.
Placethe chokelever in the "Closed" position
(Figure5).
Closed
Setthe engine switch to the "On" position (Figure6).
EngineSwitch
Off
On
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.
/7

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.
i8

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
f
(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
•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.
/9

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

DON'T OVERLOAD YOUR
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 I I.
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
8O0
50O
50O
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
Surge Watts
Power Management
To prolong the life of your generator and attached devices,
it is important to take care when addingelectrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it's engine.The correct
and safeway to managegenerator power isto sequentially
add loads asfollows:
I. With nothing connected 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 loads than the generator capacity.Take
specialcare to consider surgeloads in generator capacity,
asdescribed above.
Tool or Appliance
Essentials
Light Bulb - 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
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
Rated*
(Running)
Watts
75
500
8O0
8O0
1000
12O0
3OO
8O0
1000
1500
1500
2500
Additional
Surge
(Starting)
Watts
5O0
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.
/II

SPECIFICATIONS
Maximum SurgeWatts ................. 5,625 watts
Continuous Wattage Capacity ........... 4,500 watts
Power Factor .............................. 1.0
Rated Maximum Continuous AC Load Current:
At 120Volts ....................... 37.5Amps
At 240 Volts ....................... 18.7Amps
Phase................................. I-phase
Rated Frequency ....................... 60 Hertz
FuelTank Capacity................... 7 U.S.gallons
ShippingWeight ......................... 164 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 engineowner's manualfor instructions.
Maintenance Minder
The maintenance minder displaysand records how many
hours your generator has run (up to 9,999.9).It also alerts
you when to changeyour oil and to service your air filter.
The message"CHG OIL" will flash after the first 20 hours
of unit operation.This isto remind you to replace the
'break-in' oil with regular duty oiLThe same messagewill
againflash after intervalsof 100 hours.The maintenance
reminder does not sensethat the oil changehasoccurred -
it merely flashesthe messagefor a two hour period to
permit you to observe the reminder.
Similarly,the message"SVC AIR FILTER" willflash after
intervalsof 50 hours to remind you to service or change
the air filter element
_ii CAUTION!When working on the generator,
alwaysdisconnect spark plug wire from spark plug
and keepit awayfrom spark plug.
_ii AUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to causeskin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soapand water.
KEEPOUT 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 dean dry
environment where it w{{{ 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 dean generator.
Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air slots,
some of the water wilt 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
_ii AUTION! NEVER insertany object or tool
through the air cooling slots, even ifthe engine is
not running.
• 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. Inspectcooting air slots and opening on
generator.These openings must be kept clean and
unobstructed.
/12

STO RAG E
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,usethe following guidelinesto prepare it for
storage.
Generator Storage
•Clean the generator asoutlined in"To Clean the
Generator"
• Check that cooling air slots and openings on generator
are open and unobstructed.
_AUTION! Storage covers canbe flammable.
DO NOT place a storage cover over a hot
generator. Let the unit coot for a sufficient time
before placingthe cover on the unit.
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 fuel. 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 fuel 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

NOTES
14

TROUBLESHOOTING
Problem
Engine is running, but
no AC output is
available.
Engine runs good but
bogs clown when
loads are connected.
Engine will not start;
or starts and runs
rough.
Cause
I. Circuit breaker isopen.
2. Poor connection or defective cord set.
3. Connected device isbad.
4. Fault ingenerator.
I. Short circuit in a connected load.
2. Generator is overloaded.
3. Enginespeed istoo slow.
4. Shorted generator circuit.
I. Engineswitch set to "Off'.
2. Low oil level.
3. Dirty air cleaner.
4. Out of gasoline.
5. Stalegasoline.
6. Sparkplug wire not connected to
spark plug.
7. Badspark plug.
8. Water in gasoline.
9. Overchoking.
10. Excessivelyrich fuet mixture.
I I. Intake valve stuck open or closed.
12. Enginehaslostcompression.
Solution
I. Resetcircuit breaker.
2. Check and repair.
3. Connect another device that is ingood
condition.
4. Contact Generac service facility.
I. Disconnect shorted electrical load.
2. See"Don't Overload the Generator" on
page II.
3. Contact Honda service facility.
4. Contact Generac service facility.
I. Setswitch to "On".
2. Fill crankcaseto proper level.
3. Cleanor replace air cleaner.
4. Fillfuet tank.
5. Drain gastank and fill with fresh fuel.
6. Connect wire to spark plug.
7. Replacespark plug.
8. Drain gastank; fill with fresh fuel.
9. Setchoke to "Off' position.
10. Contact Honda service facility.
I I. Contact Honda service facility.
12. Contact Honda service facility.
Engine shuts down I. Out of gasoline. I. Fitl fuet tank.
during operation. 2. Fault in engine. 2. Contact Honda service facility.
I. Load istoo high. See "Don't Overload the Generator" on
page II.
Engine lacks power. 2. Dirty air filter. Replace air filter.
3. Engine needs to be serviced. Contact Honda service facility.
I. Choke is opened too soon.
Engine "hunts" or
falters. 2. Carburetor is running too rich or too
lean.
I.
2.
3.
I.
2.
Move choke to halfway position titl engine
runs smoothly.
Contact Honda service facility.
/15

SCHEMATIC
BATTERY CHARGE
55
L 77 12V PC
HOURMETER/
MAINTENANCE REMINDER
IIA
11
IIA
IIA
66
13 55
RESET
lOA CB
13
IIA
14)
/ff) EXOTATION
FIELD
POWER POWER
ii 22 44
IDLE
CONTROL
TRAN3FORMER
155 156 22 44
IDLE CONTROL
CIRCUIT BOARD
IDLE
SWITCH
22
120/240V
30A 44A
22 22
44A
IIA
I
16

WIRING DIAGRAM
IIA
IlA
IIA
ii
20A CB ]20/240V 30A
IDLE CONTROL
SWITCH
120V 20A
GFCI
12V/IOA DC
0
22
L 22
F 156
13 155 GRY
GR%
IIA
44
55
55
13
13
13 DC CB t5
55
15
13 156
155 ORY
CRY
I17

2 ¸ _rs
EXPLODEDVIEW- MAIN UNIT
48 \\
51 52\
33'\
31
42 76
56
72
65
10
61
27 2B
\\25
19
37_
11\\
3
\\\\\\
1
16
15 17
20
2
_ 6_
66
/18

2 ¸ _r3
PARTS LIST - MAIN UNIT
Item Part # Qty
IK189252GS I
2 67989GS 8
3 70642GS 2
4 76222GS 2
5 91844JGS I
6 66365GGS I
7 SRV66825DGS I
8 26850GS 2
9 86494GS I
10 67022GS I
II 86307GS 4
12 22695GS I
13 86308CGS 4
14 189127GS I
15 74908GS 4
16 B4871GS I
17 66849GS 2
18 91825GS I
19 84242GS I
20 B4986GS I
21 20566GS I
22 85652GS 2
23 22769GS
24 86292GS
25 189540GS
26 81917GS
27 47480GS
28 96796GS
30 14353621GS
31 38750GS
32 22097GS
33 22473GS
34 BI89434GS
35 42909GS 2
36 22145GS 2
37 22129GS 2
38 45771GS 2
39 78299GS I
40 80270GS I
41 48031CGS 2
Description
CRADLE
NUT
MOUNT, Vibration
SCREW
ASSY,Rotor
HOUSING,Adapter
CARRIER,Rear Bearing
WASHER
SCREW,Wing
GROMMET,Rubber
SCREW
CONNECTOR, 6-pin Male
BOLT,Stator
GROMMET,Bushing,Rubber
SCREW
COVER, Bearing Carrier
SCREW
ASSY,Brush & Bridge Rectifier
GROMMET,Plastic,RBC
DECAL, Ground
DECAL, b800
MOUNT, Vibration
WASHER
SCREW
ASSY,Stator
PIN,Roll
BOLT,Rotor
WASHER
ASSY,Wire, Ground
SCREW
WASHER, Lock
WASHER
COVER, Engine
SCREW
WASHER
WASHER, Lock
NUT
BUSHING, GasTank
VALVE,Fuel
CLAMP,Hose Band
Item Part #
42 30340GS
43 189564GS
44 83465GS
45 78831AGS
46 93826GS
47 B4363GS
48 188333GS
49 B1998AGS
50 92982GS
51 189273GS
52 189272GS
53 189275GS
54 77816GS
55 73054GS
56 189274GS
57 189155GS
58 J189384GS
59 B2153GS
60 22413GS
61 22473GS
62 189377GS
63 189249GS
64 BB3061BGS
65 B1464GS
66 189264GS
67 65787GS
68 43438GS
69 84409GS
70 23762GS
71 189521AGS
72 66849AGS
73 65795GS
74 189454AGS
76 56893GS
77 BI232GS
78 28739AGS
900 NSP
Qty Description
I HOSE,Fuel
I CONNECTOR, Reducer
4 GROMMET,Tank
4 SCREW
I DECAL, Start Instructions
I CAP,Fuel Gauge
I DECAL, Instructions, Fuel Level
I ASSY,Tank,Fuel
(Includes Items 39 & 40)
DECAL, Danger
DECAL, Unit
DECAL, Control Panel
DECAL, Powered By Honda
DECAL, Caution, Hot Muffler
DECAL, FuelShut-Off
DECAL, Starting Instructions
WASHER
HEAT SHIELD,Muffler
SCREW
SCREW
WASHER
NUT,Well
ASSY,Control Panel
(see page21)
BOTTLE,Oil
MANUAL, Engine
MANUAL, Owners
CABLE, Battery Charge
PLUG, 120/240V,30A
SLEEVING,Flexo
WASHER
WIRE, PanelGround
SCREW
RECTIFIER
WIRE, Rectifier
SCREW
CLAMP,Hose
WRAP,Tie
ENGINE
/19

2 ¸ _r3
EXPLODEDVIEWAND PARTS LIST-WHEEL KIT
32
/
4
10'
Item Part # Qty Description
I BB5586GS 2 HANDLE (Includes Item 15)
2 B4966GS 2 WHEEL
3 191267KGS IAXLE
4 191265GS 2 E-RING
5 39287GS 2 SCREW
6 BI89522GS ILEG,Support
7 191413GS 2 MOUNT, Vibe,with Washer
8 42909GS 2 SCREW
9 52858GS 4 NUT, Lock
10 22247GS 2 WASHER
II 39253GS 2 SCREW
12 22145GS 4 WASHER
13 49820GS 2 NUT
14 187104GS 4 WASHER, Nylon
15 B4605GS 2 GRIP
16 B4135GS 2 PIN, with Lanyard
/20