Generac 1642-2 Owner’s 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-portables.com or www.briggsandstratton.com

Model No. 1642-2 (5,500WattAC Generator) Manual No. 189439GS Revision I (10/15/2002)

EQUIPMENT

DESCRIPTION

_Read this manual carefully and become

familiar with your pressure washer. Know its
applications, its limitations and any hazards

involved.

This generator isanengine-driven, revolving field,alternating
current (AC) generator. It was designedto supply electrical
power for operating compatible electrical lighting,appliances,
tools and motor loads.The generator's revolvingfield is
driven at about 3,600rpm by a single-cylinder engine.

CAUTION! DO NOT exceed the generator's
wattage/amperage capacity.See"Don't Overload the

Generator" on page 10.

Everyeffort has beenmadeto ensure that information inthis

manualisaccurate and current However,Generac reserves
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.

DANGER

Operate generator ONLY outdoors.
Keep at least 2 feet of clearance on all sidesof generator for

adequateventilation.
DO NOT operategeneratorinsideanybuildingor enclosure,

includingthe generator compartment of a recreationalvehicle(RV).

DANGER

National ElectricCode requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.

DANGER

SAFETY RULES

The safetyalert 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 hazard which, 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 injury or death.

In the State of California a spark arrester is required by lawI
(Section 4442 of the California Public ResourcesCode).

Other states may havesimilar laws.Federal laws applyon
federal lands.Ifyou 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.

When usinggenerator for backup power, notify utility
company.Use approved transfer equipment to isolate

generator from electric utility.
Use a ground circuit fault interrupter (GFCI) in any damp or

highly conductive area,such as metal 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.

WARNING

ENERATOR

Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.

/

2

, WARNING

, WARNING

WHEN ADDING FUEL

Turn generator OFF and let it cool at least2 minutes before

removing gascap.Loosencap slowly to relieve pressure in tank_
Fill fuel tank outdoors.

DO NOT overfill tank.Allow space for fuel expansion.
Keepgasoline 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 angle which causes

gasoline to spill.

tHEN TRANSPORTING OR REPAIRING EQUIPMENT

Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFE

Disconnect spark plug wire.

NHEN STORING GASOLINE OR EQUIPMENT WITH

FUEL IN TANK

Store awayfrom furnaces,stoves,water heaters, clothes
dryers or other appliancesthat havepilot light or other

ignition source becausethey can ignite gasoline vapors.

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 Your Generator" on page IO.
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.

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.

CAUTION

Use generator only for intended uses.
if you have questions about intended use,askdealer or

contact Generac.
Operate generator only on level surfaces.

DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.

DO NOT insert any obiects through cooling slots.
if connected devices overheat, turn them off and disconnect

them from generato_
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.

FuelTank

SparkArrester Muffler

Choke Lever

Circuit

Air Cleaner

Recoil Starter

Breakers (AC)

120/240Volt AC,

30 Amp
Receptacle

Rocker Switch
(on engine shroud)

120Volt AC, 20 Amp, Duplex Receptacles -- Maybe

usedto supply electrical power for the operation of

120Volt AC, 20 Amp, singlephase,60 Hz electrical, lighting,

appliance,toot 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.

/

Grounding Wing Nut

120Volt AC, 20 Amp

Duplex Receptacles

Oil Fill

Circuit Breakers (AC) -- Pushto reset circuit breakers
are provided to protect the generator againstelectrical

overload.

Fuel Tank -- Capacity of five (5) U.S.gallons.
GroundingWing Nut -- Used for proper grounding of

unit (seepage 7).
Oil Fill --Add engine oil here.

Recoil starter -- Used to start the engine.
Rocker 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

Install Wheel Kit

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.

IMPORTANT: Any attempt to run the unit before it has

been serviced with the recommended oil will result in an
engine failure.

Remove Generator From Carton

• Set the carton on arigid fiat surfacewith "This SideUp"

arrows pointing upward.

• Carefully open the top flaps of the shippingcarton.

• Cut down corners at one end of carton from top to
bottom andlaythat side of carton down fiat

• Removeall packing material, carton fillers, etc.

• Removethe generator from the shipping carton.

IMPORTANT:This wheel kit is not intended for
over-the-road use.

To installyour wheel kit you need the followingtools:

• Two 13mm box,open end,or socket wrenches
Install Wheel Kit as follows:

I. Placethe bottom of the generator cradle on a fiat,

even surface.Temporarily place unit on blocks to ease
assembly.

2. Slide axle through both axle mounting brackets on
cradle frame, as shown in Figure I.

3. Slide a wheel over the axle.

NOTE: Besure to install both wheels with the air
pressure valve on the outboard side.

4. Placethe e-ring onto the groove in the axle.You may
add the fiat washer if desired.

NOTE: Use retaining pins instead of e-ctip, if applicable.

5. 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 pressingthe pliers closed.

Handle Assembly

Cap Screw

\

\

\

Hex Nut _

\

\

FlatWasher

Cap Screw

/

Axle

/

Wheel

/

/

/

E-Ring

5

6. Repeatstep3through5tosecuresecondwheel.

7. Removethetemporaryblocks.

8. Toaidsupportlegassembly,restgeneratoroncradle,
engineenddown.Attachthesupportlegwithtwo

M8x 16mmcapscrewsandtwolockinghexnutsas

shown.

9. Usetwo13mmwrenchesto tightenleghardware.

Restgeneratoronwheelsandsupportleg.

IO.Centerthehandlebracketongeneratorframeat

supportlegendofcradle,asshown.

II. AttachhandlebracketwithtwoM8x45mmcap

screwsandtwolockinghexnuts.

12.Checkthatallfastenersaretightandthetiresare
inflatedbetween15-40PSI.

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:

• Place generator on a level surface.

• Follow the oil grade recommendations and oil fill
instructions given in the engine owner's manual.

NOTE:The generator's revolving field rides on a
prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.

Add Gasoline

_ ARNING! 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.

_ 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 gasoline to fuel tank. Be
careful not to overfill.Allow about 1.5"of tank spacefor
fuel expansion (Figure 2).

Fuel

..... N 22Nr

• Install fuel capand 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
leadsto separation and formation of acids during storage.
Acidic gascan damagethe fuel system of an engine while in

storage.
Be sure to review the precautions given in "Storage" on

page 12.NEVER use engineor carburetor cleaner products
in the fuel tank or permanent damagemayoccur.

/

6

GROUNDING THE

OPERATING 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

)rovided on the generator end (Figure 3).

Grounding
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.

G EN ERATO R

A AUTION! NEVER start or stop the engine

with electrical loadsconnected to the receptacles
AND with the connected devicesturned 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. Placethe choke lever in the "Choke" position
(Figure5).

/

7

3. Settherockerswitchto"On"position(Figure6).

4. Grasp the recoil handle and pull slowly until slight
resistance is felt.Then putl rapidly to start engine.

5. Move choke lever to "Run" position a short distanceat

a time over severalsecondsin warm weather or
minutes incold weather.Let engine run smoothly before

eachchange.Operate with choke in"Run" position.

NOTE: If engine stilt fails to start after 3 pulls,check for
proper oil levet in crankcase.This unit is equipped with a
low oit device which prevents the engine from being
started. 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.

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

single phase,60 Hz electrical loads.

• DO NOT connect 240VoIt 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 10.

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 rocker switch to "Off' position.

• Movethe fuel valve to the "Off' position.

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) (Figure7).You can use the same4-wire cord if you

)lan to run a 120Volt load.

4-Wire Cord 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 5,500 watts of power (5.5 kW)
at 30Amps for 120Volts or 240Volts.The outlet is
protected by a push-to-reset circuit breaker.

_ CAUTION! Although this outlet states it hasa

120/240Volt 22.9Amp rating (up to 7,200 watts),

the generator isonly rated for 5,500 watts.

Powering loads that exceed the wattage/amperage

capacity of the generator candamageit or cause

serIOUS injuries.

/

8

120 Volt AC, 20 Amp, Duplex

Receptacles

Eachduplex receptacle (Figure 8) isprotected against
overload by a push-to-reset circuit breaker.

laT_[l_l:a_mlP,T*)kv_f_p,T,]r_D_]._ l _r4

I

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 20 Amps (or greater).

COLD WEATH ER

OPERATION

Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icingof the carburetor and/or the crankcase
breather system.

Build a structure that wilt enclose three sides and the top
of the generator:

• Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from that
shown in Figure 9.

_ CAUTION!These outlets are rated at 120Volt

20 Amp each (up to 80 Amps).The generator isonly
rated for up to 45.8Amps. Powering loadsthat

exceed the wattage/amperagecapacity of the
generator can damageit or cause serious injuries.

• Ensure a minimum of two feet clearance between open
side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the
generator to prevent problems.

_ AUTION! NEVER run unit indoors. DO NOT

enclose generator any more than shown. Remove
generator from shelter when temperature is above
40°F [4°C].

I

9

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 items running. SeeFigure I0.

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 as acircular 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)

Total Rated (Running)Watts = 3075

Highest Additional SurgeWatts = 1800

Total Generator Output Required = 4875

Rated (Running)

Watts

1200

800
500

500

75

3075 Total

Running 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 safewayto managegenerator power is to sequentially

add loads as follows:

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.

Additional Surge

(Starting) Watts

1800

1600
500

1800 Highest
SurgeWatts

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.

Rated*

Tool or Appliance

Essentials

Light Bulb - 75 watt
Deep Freezer
SumpPump
Refrigerator/Freezer - 18 Cu. Ft.

Water Well Pump - I/3 HP

Heating/Cooling

Window AC - I0,000 BTU
Window Fan

FurnaceFanBlower - 112HP

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 - 1/2 HP
Electric Water Heater - 40 Gallon

DIY/Job Site

Quartz Halogen Work Light

Airless Sprayer - I/3 HP

Reciprocating Saw
Electric Drill - 1/2 HP

Circular Saw- 7 I/4"

Miter Saw - I0"
Table Planer - 6"
Table Saw/RadialArm Saw- I0"

Air Compressor - I-I/2 HP

*Wattages listed are approximate only. Check toot or
appliance for actual wattage.

(Running)

Watts

75

500
8O0

8O0

1000

12O0

3OO
8O0

1000
1500

1500

25O0

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

Additional

Surge

(Starting)

Watts

500

1200
1600

20O0

1800

6O0

1300

/

I0

SPECIFICATIONS

Maximum SurgeWatts ................. 8,500 watts

Continuous Wattage Capacity ........... 5,500 watts

Power Factor .............................. 1.0

Rated Maximum Continuous AC Load Current:

At 120 Volts ....................... 45.8 Amps

At 240 Volts ....................... 22.9 Amps

Phase ................................. I-phase

Rated Frequency ....................... 60 Hertz

Fuel Tank Capacity ................... 5 U.S.gallons

Shipping Weight ......................... 163 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 manual for instructions.

If you need service for your engine, you need to determine

the engine identification number.To do so, remove the

rocker arm cover hood, item number 55 shown on

page 16, by removing the four nuts and washers holding it
in place.The engine model-type-trim number is stamped on
the side of the inner cover attached to the engine. Have
this number in hand when you call the engine service

center for assistance.

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 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

A AUTION! NEVER insert any object or tool

through the air cooling slots, even if the 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. Inspect cooling air slots and opening on

generator.These openings must be kept clean and
unobstructed.

A AUTION! Avoid prolonged or repeated skincontact with used motor oil. Used motor oil has

been shown to causeskin cancer in certain
laboratory animals.Thoroughly wash exposed areas

with soap and water.
KEEPOUT OF REACH OF CHILDREN. DON'T

POLLUTE.CONSERVE RESOURCES.RETURN
USED OIL TO COLLECTION CENTERS.

/

II